CN1009231B - Improved toroidal transformer and manufacturing equipment thereof and method - Google Patents

Abstract

A kind of ring-shaped transformer has a low-voltage coil, a high-tension coil and a ring-like magnetive cord.Low-voltage coil of preferentially selecting for use and high-tension coil are continuous and form the arch form passage that stretches, the ring-like magnetive cord of preferentially selecting for use is formed around going into above-mentioned arcuate channels by continuous magnetic band, has continuous coil becomes the continuous reeling shape with iron core ring-shaped transformer thereby also just formed.The invention still further relates to method and the equipment thereof of making this ring-shaped transformer and parts and sub-unit.

Description

Improved toroidal transformer and manufacturing equipment thereof and method

In being 0083567 European patent, a publication number please disclose a kind of equipment of making toroidal transformer.This equipment with the magnetic core band from the inner ring of core material volume deviate from and with the magnetic core band around go into toroidal transformer in advance around the primary and secondary winding.This equipment comprises a turntable, and this turntable makes reel its axis and unclamp direction rotation continuously the curls inward of volume towards the magnetic core band from core material of core material, and a coiler device, be used for the magnetic core band around go in advance around elementary secondary winding.

The present invention relates to a kind of equipment of making annular transformation.This equipment be the inner ring of the core material of magnetic core band volume is deviate from and with the magnetic core band around go into toroidal transformer in advance in the primary and secondary winding, this equipment comprises a turntable, this turntable makes core material its axis of reeling, and unclamp the direction rotation the inner ring of volume continuously towards the magnetic core band from core material, and a coiler device, be used for the magnetic core band around go in advance around the primary and secondary winding.Characteristics of the present invention are that magnetic core band and maintenance magnetic core band that the orienting device that is provided is used for accepting from the core material volume is deviate from leave the direction that core material is rolled up, and device that the magnetic core band is produced resistance, when the core material volume unclamps, this resistance is pushed band to inner ring circle that core material is rolled up, and minimum degree is reduced in the bending when making band leave inner ring; Described device and the orienting device that the magnetic core band is produced resistance works to the magnetic core band jointly, in the opposite direction of ribbon motion band applied a frictional force; Described orienting device relies on gravity that band weight produces with the inner ring of magnetic core band to the core material volume, makes the band of deviating from from inner ring always towards the direction that makes progress; Described turntable is around the concentric axis rotation of itself and core material volume.

The invention still further relates to a kind of method of making toroidal transformer, this method be with the magnetic core band from the inner ring of core material volume deviate from and with it around going into the pre-around elementary secondary winding of toroidal transformer.This method realizes by following steps: make core material reel its axis and the volume inner ring unclamps continuously towards the magnetic core band from core material direction rotation; With band around go in advance around the primary and secondary winding in.Be characterized in that by in going into primary and secondary winding process, band is to deviate from and have a resistance to execute thereon from the inner ring of core material volume at band, push band the inner ring of core material volume to, minimum degree is reduced in the bending when making band deviate from inner ring.

Accompanying drawing of the present invention is summarized as follows:

Fig. 1 is the part perspective view of a toroidal transformer of preferentially selecting for use of the present invention.

Fig. 2 is the cut-away section top view of toroidal transformer shown in Figure 1, the supporting structure of having omitted transformer among the figure.

Fig. 3 is the cross-sectional view of part toroidal transformer, cuts the supporting structure that ， And has omitted transformer open from the line 3-3 of Fig. 2.

Fig. 4 is the perspective view of the magnetic core insulated tube preferentially selected for use of a part of the present invention.

Fig. 4 a is the fragmentary, perspective view of a part of insulating component of the toroidal transformer preferentially selected for use, has marked the structure of standard cooling liquid bath.

Fig. 5 is the decomposition diagram of the high-low pressure insulating case preferentially selected for use of a part of the present invention.

Fig. 6 is the decomposition diagram of magnetic core bobbin of the present invention.

Fig. 7 is before magnetic core is installed, the assembling schematic diagram of each main part of transformer.

Fig. 8 is the block diagram according to a kind of manufacturing toroidal transformer method of preferentially selecting for use of the present invention.

Fig. 9 is total view of the low-voltage coil coil winding machine preferentially selected relevant with the present invention.

Figure 10 is the perspective view with several coils of the low pressure winding of low-voltage coil coil winding machine manufacturing shown in Figure 9.

Figure 10 a is the plane graph that several coils of Figure 10 mesolow winding section from 10a-10a.

Figure 10 b is the perspective view of low-voltage coil coil winding machine forming rolls tire shown in Figure 9.

Figure 11 is the front view of low-voltage coil coil winding machine shown in Figure 9.

Figure 12 is the perspective view of a distortion sub-unit of low-voltage coil coil winding machine shown in Figure 9.

Figure 13 is the exploded view of a distortion sub-unit shown in Figure 12.

Figure 13 a shows the perspective view of distortion caster bed with pivotal mounting.

Figure 14 is a low-voltage coil coil winding machine shown in Figure 9 cross sectional detail along the 14-14 place of Figure 11.

Figure 15 is the front view of a forming rolls tire sub-unit of low-voltage coil coil winding machine shown in Figure 9.

Figure 16 is the exploded view that be linked and packed structure and the side pressure of low-voltage coil coil winding machine shown in Figure 9 rolled.

Figure 17 to Figure 24 is the distortion head of low-voltage coil coil winding machine shown in Figure 9 and the series of drawing of forming rolls tire sub-unit.

Figure 17 is the front view that twists head and forming rolls tire sub-unit when the primary cable coil is in the shaping initial period.

Figure 17 a is the cross sectional detail of a part distortion sub-unit at Figure 17 a-17a section.

Figure 18 is when the primary cable coil is in the shaping after-stage, the front view of the part parts of distortion head and forming rolls tire.

Figure 18 a is that part is twisted a sub-unit in Figure 18,18a-18a place cross sectional detail.

Figure 19 is the front view that twists head and forming rolls tire sub-unit when the primary cable coil is in the shaping after-stage.

Figure 19 a is the cross sectional detail in part cross section, 19a-19a place in Figure 19 of a distortion sub-unit.

Figure 20 is the front view that twists head and forming rolls tire sub-unit when the primary cable coil is in the shaping after-stage.

Figure 20 a is part 20a-20a place cross-sectional view in Figure 20 of a distortion sub-unit.

Figure 21 is when the primary cable coil is in the shaping after-stage, the cutaway view of distortion head and forming rolls tire sub-unit.

Figure 21 a is the cross sectional detail at part distortion sub-unit 21a-21a place in Figure 21.

Figure 22 is when primary cable coil forming after-stage, the end view of part distortion head and forming rolls tire sub-unit.

Figure 22 a is the cross sectional detail at part distortion sub-unit 22a-22a place in Figure 22.

Figure 23 is when primary cable coil forming after-stage, the end view of distortion head and forming rolls tire sub-unit.

Figure 23 a is the cross sectional detail at part distortion sub-unit 23a-23a place in Figure 23.

Figure 24 is when primary cable coil forming after-stage, the end view of distortion head and forming rolls tire sub-unit.

Figure 24 a is the cross sectional detail at part distortion sub-unit 24a-24a place in Figure 24.

Figure 25 is the front view of the storage roller tire sub-unit of low-voltage coil coil winding machine shown in Figure 9.

Figure 26 is the exploded view of storage roller tire sub-unit shown in Figure 25.

Figure 27 is the exploded view of the additional distortion cam gear shaped portion of storage roller tire sub-unit shown in Figure 25.

Figure 28 is the sectional detail drawing at additional distortion cam gear 28-28 place in Figure 15 shown in Figure 27.

Figure 29 a is the sectional detail drawing at additional recking means for cargo 29-29 place in Figure 28 before additional winding.

Figure 29 b is the sectional detail drawing at additional distortion cam gear 29-29 place in Figure 28 when adding winding.

Figure 29 c is after additional winding, the additional distortion cam gear when being in certain position in Figure 28 the 29-29 place cut open detail drawing.

Figure 30 is in additional winding, stores the end view of roller tire assembly.

Figure 31 a is the plane graph of a kind of selective concrete device of low pressure winding.

Figure 31 b is the view that distortion head and roller are shaped in the outside of the low pressure winding shown in Figure 31 a.

Figure 31 c and Figure 31 e are that roller and distortion head are positioned at the inner view that is shaped of the low pressure winding shown in Figure 31 a.

Figure 32 a is the plane graph of several coils of the another kind of selective concrete device of low pressure winding.

Figure 32 b is that the distortion head is at the outside bottom view that is shaped of the low-voltage coil shown in Figure 32 a.

Figure 32 c is the bottom view of the distortion head of Figure 32 b in the inner shaping of the low-voltage coil shown in the 32a.

Figure 32 d is the section detail drawing that is used for the outside forming rolls tire that is shaped of low-voltage coil shown in Figure 32 a.

Figure 32 e is the section detail drawing that is used for the inner forming rolls tire that is shaped of low-voltage coil shown in Figure 32 a.

Figure 33 is total figure of a kind of high-tension coil coil winding machine of preferentially selecting for use that the present invention describes.

Figure 33 a is the detail drawing of metal wire arrangement components of the part of high-tension coil coil winding machine shown in Figure 33.

Figure 34 is the roller tire of high-tension coil coil winding machine shown in Figure 33 and the detailed side view that the roller fetal position is measured.

Figure 34 a is the roller tire of Figure 34 and the perspective view of roller fetal position measurement mechanism.

Figure 35 to Figure 38 is the roller tire of high-tension coil coil winding machine shown in Figure 33 and the series of drawing of metal wire arrangement components.

Figure 35 is the end view of high-tension coil coil winding machine roller tire and metal wire arrangement components when initial period.

Figure 35 a is the front view of roller tire, presses the arrow 35a direction among Figure 35.

Figure 36 is the end view of high-tension coil in coiling after-stage pair roller tire and metal wire arrangement components.

Figure 36 a is the section detail drawing of roller tire, and the 36a-36a from Figure 36 cuts open.

Figure 37 is a high-tension coil when the coiling after-stage, the end view of roller tire and metal wire configuration sub-unit.

Figure 37 a is the section detail drawing of roller tire.37a-37a from Figure 37 cuts open.

Figure 38 is a high-tension coil when the coiling after-stage, the end view of roller tire and metal wire configuration sub-unit.

Figure 38 a is the cross sectional detail at the 38a-38a place of section in Figure 38 of roller tire.

Figure 39 is a high-tension coil when the coiling after-stage, the section detail drawing of roller tire.

Figure 40 is the perspective view that the metal wire of high-tension coil coil winding machine use disposes the another kind of selective concrete device of orienting device.

Figure 40 a is the cross sectional detail of a kind of selective concrete device of coil winding machine shown in Figure 40 and metal wire configuration orienting device.

Figure 41 is the end view that the metal wire of high-tension coil coil winding machine use disposes a kind of selective concrete device of orienting device.

Figure 42,42a and 42b are that the magnetic core of preferentially selecting for use that the present invention uses is involved in the machine view.

Figure 43 is that magnetic core shown in Figure 42 is involved in machine and magnetic core is deviate from sub-unit section detail drawing.

Figure 44 is the front view that magnetic core shown in Figure 43 is driven out the machine sub-unit.

Figure 45 is the part section detail drawing that magnetic core that magnetic core shown in Figure 42 is involved in machine is involved in sub-unit.

Figure 46 is used for the section detail drawing that magnetic core shown in Figure 45 is involved in the bobbin of sub-unit.

Figure 47 is the end view that magnetic core shown in Figure 45 is involved in sub-unit.

Figure 48 is the part section front view that magnetic core shown in Figure 45 is involved in sub-unit.

Be the description of several special concrete devices below.

In Fig. 1 to Figure 48, only for illustrative purposes, the various concrete device of preferentially selecting for use provided by the present invention has been described.

By following discussion, any those skilled in the art that can recognize easily that the concrete application of described alternative structure and method can not break away from basic principle set forth in the present invention.

Fig. 1 to Fig. 3 has illustrated a toroidal transformer of preferentially selecting for use 10, and it is made up of the circle or the toroidal core 20 of continuous coiling, and this magnetic core 20 is inserted in the magnetic core insulated tube 30.Low-voltage coil or winding 40 are to surround around magnetic core insulated tube 30 De ， And and by high/low pressure insulating case 50, and high-tension coil or winding 60 will surround around the insulating case 50 again.

High pressure winding 60 is made up of two semi-circular portions 61 and 62 basically, each semi-circular portions all contains a plurality of cake formula or wedge-type coils by the continuous coiling of common metal line, they are connected by the ring of described common metal line, 20 8.25 ° of coils are for example arranged in each semi-circular portions, formed about 165 a ° arc.At least, high pressure winding 60 near semi-circular portions 61 and 62 ends, separate effectively with the insulating barrier or the axle collar 70, above-mentioned metal wire loop extends around the axle collar, can stop the influence of impact stress, this influence comes from any non-linear voltage and distributes to add to and produce after the high-tension coil that is connected, and for example, the impacting with high pressure process causes as igniting.Sometimes in all high pressure winding arch sections, requiring has one or more dividing plate 70, as shown in the figure.Dividing plate 70 contains radial flange ， And that each adjacent windings with high pressure winding 60 separates and this dividing plate plastic cardboard by standard, and brown paper or synthetic insulating material are formed, for example: " MYLAR " or " KAPTO и ".Dividing plate 70 is kept going up in position by plastic cuff or flange 71, this flange 71 high pressure winding arch section to around or extend axially, as shown in Figure 2.

Similarly, the low pressure winding of preferentially selecting for use 40 also is made up of two semicircles parts 41 and 42 basically, and is opposed with high pressure winding part 61 and 62.This low pressure winding semi-circular portions 41 and 42 of preferentially selecting for use contains sub-thread, bifilar or lead that multiply is parallel respectively, and these leads all have an alternately arrangement architecture, and a this parallel lead of voltage winding will be known clearly below and be reached.In the concrete device of preferentially selecting for use, as shown in the figure, high pressure winding part 61 and 62 and low pressure winding part 41 and 42 be to circumferentially extend respectively, until every limit of transformer 10 is shaped till about 165 ° arc.Corresponding magnetic core insulated tube 30 and high/low pressure insulating case 50 are made up of two semi-circular portions, and each semi-circular portions is along the circumferential direction to extend, and have approximately till 165 ° the arc until every limit of transformer 10 forms.Low-voltage coil 40 is to be inserted in about 165 ° girth that De ， And in the high-tension coil 60 and two coils have surrounded toroidal core 20.

Here employed term " continuously " is to comprise a structure of preferentially selecting for use in high pressure winding or coil 60 and semi-circular portions 61 and 62, wherein contain and be wound into cake formula wire harness or coil and shackle, these wire harness or coil and connecting ring can be made with single strand wire or bundle conductor; Single strand wire or lead are continuous in high-tension coil semi-circular portions 61 and 62, in other words, are continuous at 1/2nd places of toroidal transformer 10.This term " continuously " also is related to the various replacement structures of high-tension coil 60, and in this structure, cake or coil can be with continuous metal wire or lead coileds.

About low pressure winding or coil 40 and semi-circular portions 41 and 42, using term " continuously " is to comprise the sub-thread of describing, and bifilar or multiply is arranged, and wherein lead is continuous on low-voltage coil semi-circular portions 41 and 42.In this concrete device of preferentially selecting for use, low-voltage coil is continuous on the semicircle part of toroidal transformer 10.This term " continuously " relates to the low-voltage coil structure of any replacement, in this structure, no matter primary cable can be sub-thread, multiply, alternately arrange or alternately do not arrange that it is continuous having three circles at least.

Term " continuously " in that explanation is used during magnetic core 20 comprises a kind of like this core const ruction, it be by the continuous core material of sub-thread or multiply and continuously the core tape material of arranged in series constitute, coiling makes the very big diameter range of magnetic core 20 formation continuously.Correspondingly, though sub-thread magnetic core band coiled magnetic core in the concrete device of preferentially selecting for use, when term " continuously " then referred to turn to magnetic core with multiply magnetic core band, its actual number of turns should be greater than two circles.

Here at high-tension coil 60, employed term " circle " or " annular " are meant the structure that produces annulus in low-voltage coil 40 and the magnetic core 20, and circular ring structure is rotated around internal axis by several rules or irregular shape and forms like this.High-low pressure winding or coil 60 and 40 and the various structures of preferentially selecting for use and the shape of magnetic core 20 will describe in detail below.

Fig. 4 has described the detail drawing of the semi-circular portions 31 of the magnetic core insulated tube preferentially selected for use or insulating case 30.Insulating case 30 is formed (latter is diagram not) by two semi-circular portions 31 and 32.Although only drawn semi-circular portions 31 among Fig. 4 and Fig. 4 a, it is identical with semi-circular portions 31 that any those skilled in the art that still can identify semi-circular portions 32.

Magnetic core insulating case semi-circular portions 31 is made of an insulation and plastic cardboard, kraft liner or synthetic insulating material, and it is identical with semi-circular portions 32.Like this, forming magnetic core insulating case 30 needed two equal sections can be by a pattern manufacturing.Semi-circular portions 31 is by suitable being made by the known plastic cardboard of prior art, and perhaps the glass synthetic material example by height is that polyester, nylon or epoxide-resin glue or the like are made.

The semi-circular portions 31 of magnetic core insulated tube 30 comprises inwall 34 and outer wall 35, and each extends between bottom 36 and the top 37 vertically.This semi-circular portions adopts overall structure, can improve insulation property.

Fig. 5 has shown a semi-circular portions of preferentially selecting for use 51 of high/low voltage insulation tube or insulating case 50, and insulating case 50 contains two semi-circular portions 51 and 52.It is identical that any those skilled in the art that can identify semi-circular portions 51 and 52.The semi-circular portions 51 of high/low pressure insulating case 50 is made whole by plastic cardboard or synthetic insulating material with pattern.The inside and outside wall 55 and 56 of insulating case, each extends between bottom 57 and top 58 vertically.

The special cross section of typical circular or toroidal core insulating case 30 and high/low pressure insulating case 50, relevant with circle or toroidal core 20 with high-voltage coil and low-voltage coil 60,40.

The semi-circular portions 51 of insulating case 50 and 52 respectively is furnished with the bottom cuff 59 that is connected with its end, as shown in Figure 5.Bottom cuff 59 has the flange that extends to all around, and the inside of this flange and insulating case semi-circular portions 51 and 52 is tightly identical.Each cuff all has a radial flange, and under the condition of high pressure, flange plays an additional barrier that prevents electrical breakdown.

Figure 40 has illustrated that the part of high/low pressure insulating case 50 cuts part.The interior wall construction of preferentially selecting for use provided by the invention is arranged on the insulating case 50.Interior wall construction shown in Fig. 4 a and relevant with it discussion all are applicable to magnetic core insulating case 30.

Such transformer disclosed in this invention, in order to cool off its element, it is often to use oil or other fluids, i.e. liquid or gas in the course of the work.This cooling liquid is a kind of typical electric information insulating oil.See Fig. 4 a, high/low pressure insulating case 50 contains the ridge peak 95 on several internal layers that are positioned at outer wall 5b, and ridge peak 95 can be to tilt, spiral or inward turning or the like, between them, formed many cooling fluid stream branch roads 96.Ridge peak 95 interrupts in the bottom 57, thereby has just formed collection flow channels 97 the higher of outer wall 56 with than lower part.Branch road 96 and collection flow channels 97 work to carry cooling fluid.No matter the structure at ridge peak 95 is to tilt or helical form etc., all play the shuttling movement effect, can spread inside to high/low pressure insulating case 50 to cooling fluid, shown in the arrow among Figure 41.This circumferential movement helps the cooling of element and regulates the distribution of transformer temperature inside.

Fig. 6 is the detail drawing of bobbin 692.Bobbin 692 is used for the described method of Figure 42 to Figure 48, makes the installation of toroidal transformer magnetic core 20 become easy.Bobbin 692 comprises a sky 81 that connects two radial flanges 698 and middle cylindrical shape usually.Bobbin 692 can be limited between two radial flanges 698 with the magnetic core band on ghost 81.Inner face empty 81 have a pair of axially be spaced and to around the gear drive surface 700 of extending, be used for and insert wherein gear shaft and mesh and rotate bobbin 692.Bear surface 82 between two gear drives surface 700a and 700b, but more outstanding than gear drive surface 700a and 700b.When the coiling magnetic core, damaged or abrade by travelling gear in bobbin 692 rotary courses for avoiding magnetic core insulating material 30, this makes the magnetic core insulating material not with before gear contact, just earlier with bear surface 82 and contacted.

Bobbin 692 is made up of identical two parts 692a and 692b.Have only this two parts assembly of working as to be assembled in the appropriate section 11 and 12 of transformer, they could form complete bobbin 692.Two parts 692a of bobbin and this special construction of 692b are easy to operate in order to assemble bobbin 692.Particularly, each joint at 692a and 692b all has an axial bolt.This axial bolt contains flange 83a, and 83b, when 692a and 692b abandon fashionable, 84a just is connected with 84b, 692a692b's is axially displaced to stop, the a pair of prominent wing 85 and outer mutually groove 86 are arranged on half part of bobbin 692, and 692a and the 692b prominent wing and groove separately is meshed mutually, and this moment, the prominent wing 85 almost completely was embedded within the groove 86.In general, the prominent wing 85 is glued together or additive method sticks in the groove 86 that is meshed, and is in the internal lock state to keep 692a and 692b.

Should be noted that gear surface 700a and 700b are connected on different circumferential positions.Therefore, when tooth shaft transmission gear (seeing Figure 45-48) drove bobbin 692, every next pinion of pinion drive gear was crossed between two ones of bobbins, in order to reduce the driving force that bobbin two parts 692a and 692b trend are separated.In other words, driving two gear pinions of bobbin 692 can not be simultaneously change between the tooth of half part 692b in addition at the tooth of bobbin half part 692a and bobbin, but change with the mode of being interrupted, in order that utilize the method for the circumferential position skew of gear surface 700a and 700b joining place to compensate the imperfection of bobbin two parts 692a and 692b combination.

As mentioned above, with what bobbin two parts 692a and 692b assembled the high/low pressure coil assembly that gives first moulding arranged, comprise that insulating case 30 and 50 is together with cuff 59, then, these two parts connect into a complete bobbin 692, and And is the coiled magnetic core in winding that gives first moulding and insulating case.

In the schematic diagram of Fig. 7, two parts 11 and 12 of toroidal transformer can be respectively to the circumferencial direction expansion, till forming an about arc of 165 °, as mentioned above.The transformer portion of preferentially selecting for use 11 and 12 when it connects, just forms a basic annular of being made up of the semi-circular portions of two symmetries, and respectively there is a circle spacing that is about 15 ° at the two ends between two symmetric parts.The main application of this structure forms an arch long-channel exactly so that the continuous magnetic core 20 of coiling circle or loop configuration, as Fig. 1 to Fig. 3 and following as described in.After magnetic core coiling operation was finished, transformer part was just with supporting frame 80(to see Fig. 1) keep its distinctive shape, between transformer 10 two ends upper semi-circle parts 11 and 12, just obtained an equal interval.Then, be installed in the structure of a respective volume at transformer device, for example tube or groove 85 are seen Fig. 1.

Although the reference number of Fig. 8 and later discussion only relate to the structure and the manufacture method of toroidal transformer semi-circular portions 11, be suitable for too for second half circular portion 12 identical with semi-circular portions 11 structures.

Low-voltage coil part 41 by the coiling of twin conductor material and each circle be wound into cake formula or wedge-type (from top or below as can be known), the structure of a circle or annular is provided.Above low-voltage coil manufacturing step will describe in detail in Fig. 9 to Figure 32.

Then, low-voltage coil 41 is placed in the outside of magnetic core insulating case 31, by high/low pressure insulating case part 51 sealings, as shown in Figure 7.These sub-units are prepared for high-tension coil semi-circular portions 61.

High-tension coil part 61 is to make some cake formulas or wedge-type coil bundle or winding with continuous metal wire-wound system And.This winding process will be elaborated in conjunction with Figure 31 to Figure 41 below.

As shown in Figure 7, insulating trip 70 is placed between the high-tension coil part 61 adjacent windings that have cuff 71, and this cuff 71 extends in the annular notch of arcuate part.The outer surface ， And that high-tension coil 61 is placed on high/low pressure insulating sleeve 51 with insulating trip 70 packs bobbin 692 in the arcuate channels of magnetic core insulating case 31 into then.End cuff 59 is placed on the end (as shown in Figure 5) of insulating case 51, finishes the semi-circular portions 11 of toroidal transformer with coiling before coiling magnetic core 20.

Core material is thin class band shape or ribbon.Core material can give first coiled one and collapse tight coil ， And and can get specific length by the size that will make transformer and cut off automatically.Then Xian is enclosed Gu and Ding And and do heat treatment, to eliminate its internal stress.The loop coil that gives coiling 614 shown in Figure 42 is the semi-circular portions 11 and 12 that are used for the above-mentioned transformer of coiling.

All the other steps of winding process are: by semi-circular portions 11 and 12 at the interval of extending on the circumference with above-mentioned give reeling earlier and giving heat treated coil twist on the bobbin 692, above-mentioned parts finished product is installed on the bearing 80, finish connecting of low-voltage coil 40 and 60 of high-tension coils, above-mentioned parts are fixed in the nested structure 85.

Being described below of low-voltage coil coil winding machine.

The low-voltage coil coil winding machine is seen Fig. 9.Coil winding machine 100 has four main sub-units: format roll tire parts 102, a distortion sub-unit 104, pressure roll sub-unit 106 and storage roller tire sub-unit 326.

Format roll tire sub-unit 102 has a moulding or take up roll tire 108, this roller tire has a die cavity 110, and the cake formula die cavity that forms around the sidewall 109 in chamber and the bottom surface 111 is that bifilar primary cable 112 And that are used for accepting not moulding cooperate pressure roll that lead is turned to disc coil 113.As shown in figure 10, Figure 10 a is the cutaway view of wedge-type or disc coil 113.Figure 10 is the end view of the quadrilateral structure of coil 113.The inboard of coil is a rectangle, and the outside or outer are one trapezoidal.In addition, twist one or several side of coil.The winding of several disc coils of spooling has formed the semi-circular low-voltage coil 41 of toroidal transformer 10.Shown in Figure 10 b, at corresponding 115 places, inboard of the die cavity 110 of format roll tire 108 and coil 113, lead has increased radially that Shen Du And has reduced axial width; In opposite zone, promptly at 117 places of coil 113, lead has reduced radially spends And deeply and has increased axial width.Format roll tire 108 is fixed on the power transmission shaft; And is around axis 299 rotations, and relevant details is referring to Figure 15.Quadrangularly is generally done in the bottom surface 111 of die cavity 110.This bottom surface defines quadrangle coil 113.It should be noted that die cavity 110 for need a variable radial displacement being arranged at the axis 299 of the format roll tire 108 that twists a sub-unit 104 and 106 motions of pressure roll sub-unit, will be explained afterwards about this point.Format roll tire 108 has a groove 114, is used for accepting when moulding begins the metal wire 112a of primary cable 112 and the end of 112b.Groove 114 is angled slits, in order to accept and to keep the end of primary cable 112 when the first lap moulding.Format roll tire 108 rotates, and lead 112 is moved into die cavity 110 Zhong ， And lead 112 is curved disc coil 113, and relevant details is seen Figure 17 to Figure 24.

As shown in figure 11, a distortion sub-unit 104 provides the guider that two gangs of metal wire 112a and 112b with lead 112 send into format roll tire 108.A distortion sub-unit 104 has a distortion 116, and it can accept the two gangs of metal wire 112a and the 112b of primary cable 112 at its input 118, and And causes its output 120 along feeding axis 119 with two strands of metal wires of lead.The output 120 of distortion head or guide head 116 is used for primary cable 112 is sent to the directed and location of format roll tire 108.Be to realize the position and orientation of primary cable 112, distortion 116 must be finished three kinds of motions: rotate around its feeding axis 119, rotate and pump along horizontal pivot axis 132.

Distortion 116 is finished by tooth bar 122 around circling round of its feeding axis 119.Pinion 124 engagements of tooth bar 112 and distortion 116.Tooth bar 122 drives distortion 116 perpendicular to the front-rear reciprocation movement of feeding axis 119 and alternately does clockwise and rotate counterclockwise.Seesawing of tooth bar 122 promoted by the cylinder 126 of turning one's head.

Distortion 116 is fixed on the distortion caster bed 128, and distortion caster bed 128 is fixed on the framework 130 with pivot again and is pivoted around pivotal line 132 to limit it.The pivotal line 132 straight And that hang down intersect at feeding axis 119, are parallel to format roll tire axis 299 again simultaneously, and each pillar and the bearing that are assembled do not mark in Figure 11, and their effect is to guarantee that distortion 116 freely pivots when 108 rotations of roller tire.

Distortion caster bed 128 has two elongated grooves.This two groove can be used for accepting vertical guide stem 134, so that when distortion caster bed 128, guide rod 134 and distortion 116 pump along the path that meets at right angles approximately with roller tire axis 299 and be separated by with it, allow to twist 116 pairs of guide rods 134 and freely be pivotable.Distortion caster bed 128 depends on a distortion lift cam 136, a distortion cam follower 138, a distortion cam lift arm 140 with pumping of distortion 116 and twists movement conversion between the parts such as a cam lift bar 142.In case a distortion lift cam 136 rotates, a distortion cam follower 138 just moves up and down in the cam path 144 of a distortion lift cam 136.Moving up and down of a cam follower 138 of distortion caused cam lift arm 140 moving up and down around pivot for fixed pivot axi 146.The end 148 of a distortion cam lift arm 140 is connected the lower end of a distortion cam lever 142.When pivot moved up and down, cam lever 142 moved up and down thereupon at cam lift arm 140, ordered about again simultaneously at 150 places to move up and down with the distortion caster bed 128 that a distortion lift cam bar 142 is connected.Distortion caster bed 128 moves both vertically along a distortion guide rod 134.A distortion lift cam 136 matches with the rotation of format roll tire 108, also makes simultaneously distortion caster bed 128 and twists 116 pump and match with the rotation of roller tire 108.

Three kinds of motion modes of distortion 116 promptly rotate, swing or pivot and pump, and see Figure 17 to Figure 24 for details.The winding process of relevant primary cable 112 on format roll tire 108 also marks in the drawings in order.

Pressure roll sub-unit 106 comprises round pressure roller 152, and side pressure roller 154 and 156(side pressure roller 156 are as shown in figure 15), a left side holds roller 158 and the right side holds roller 160.Circle pressure roller 152 is fixed on the pressure roll arm 162.Pressure roll arm 162 has a stretch flange formability 164, and this flange is between a pair of ball pressure bearing pedestal 166 and 168.This moves on the vertical plane of being determined by flange 164 to bearing pedestal restriction pressure roll arm 162.On this vertical plane, circle pressure roller 152 is driven in the horizontal direction by the connecting rod 170 of a horizontal movement.The cam follower arm 172 of this connecting rod and a horizontal movement joins.In addition, justifying pressure roller 152 is driven by cam follower arm 174 in vertical direction.Horizontal movement connecting rod 170 is rolled by pressure at pivot 171 and 173 respectively with the cam follower arm 174 that moves both vertically and links together 162 sliding joining of arm.Horizontal movement cam follower arm 172 is double cam with the cam follower arm 174 that moves both vertically by pressure roll compound cam 176() drive.This double cam has a horizontal movement cam path 178 and the cam path 182 that moves both vertically.When the cam follower 180 on being fixed on cam follower arm 172 moved in cam path 178, cam follower arm 172 rotated around fixed pivot axi 184, and drive link 170 relative frameworks 130 move to left or move to right simultaneously.Moving to left or moving to right of connecting rod 170 makes pressure roll arm 162 and rotates around pivot 173 at the left end of cam follower arm 174.This rotates the horizontal reciprocating movement that causes round pressure roller 152 again.The cam path 182 that moves both vertically is used to accept to be fixed in the cam follower 186 that moves both vertically that moves both vertically on the cam follower arm 174.Pressure rolls the rotation of compound cam 176, cause moving up and down of the cam follower 186 that moves both vertically and pivoting of 174 pairs of pivots 188 of cam follower arm, also just formed pressure roll arm 162 and round pressure roller fixed thereon 152 and moved up and down at vertical plane.Compound cam 176 is to match with the rotation of format roll tire 108.For making the coil can be according to the continuous coiling of the described order of Figure 17 to Figure 24, the level of rotating the round pressure roller 152 that is transmitted by compound cam 176 with move both vertically and should match with the rotation of format roll tire 108.Put it briefly, level and vertical movement device be for making round pressure roller 152 and fit in that forming roll tire 108 rotates ， And and for fully keeping circle pressure roller 152, side pressure roller 154 and 156 and forming rolls tire 108 between the relevant position relation means are provided.

Term " level " is as the description term to described concrete device with " vertical ".Even these terms do not limited ， And may by be interpreted as widely about format roll tire 108 axis radially and horizontal movement, they also are suitable for.

The pivot 188 of cam follower arm 174 of moving both vertically is fixed on four compression springs 190.When between circle pressure roller 152 and the format roll tire obstruction or superpressure phenomenon taking place, pivot 188 can move downward limitedly like this, and circle nip drum 152 can move upward limitedly.Usually spring is in limp state when fixed pivot axi 188.The elasticity of spring 190 is higher, so only take place and position that just can mobile pivot 188 behind the spring pressurized in a certain fault.

A left side hold roller 158 and the right side hold roller 160 respectively by central beaming roller 192 and 194 and side flange 196 and 198 form.Beaming roller 192 and 194 is across between the periphery of format roll tire 108 peripheries and formed coil 113.Side flange 196 and 198 is across between formed coil 113 and the format roll tire 108, so that when format roll tire 108 rotates formed coil 113 is clamped in the die cavity 110 of format roll tire 108.Before a circle coiling of not finishing coil, formed coil 113 must not take out from the cannelure 110 of format roll tire 108, and winding process is seen Figure 17～24.

A left side holds roller 158 and is fixed on a left side and holds on the roller pivot arm 200, and this pivot arm is fixed on again on the pivot 202, to rotate in the plane shown in the figure.A left side holds roller 158 is placed in format roll tire 108 by a pressure cylinder 204 one side.This pressure cylinder is fixed between fixed pivot axi seat 206 and the pivot 208.Pivot 208 is positioned at the left left side that holds roller 158 of supporting to be held near roller arm 200 ends.

The right side holds roller 160 and is fixed on the end that the right side holds roller pivot arm 210, and this pivot arm is fixed on again on the pivot 212.The right side holds roller 160 and holds one side that pressure cylinder 214 is placed in format roll tire 108 by the right side, and the right side holds the roller pressure cylinder and is fixed on fixed pivot axi 216 and the right right side that holds roller 160 and holds between near roller pivot arm 210 pivots 218 terminal.

Referring to Figure 12, this structure of distortion head member 104 is comparatively rational.As shown in the figure, a distortion cylinder 126 has a pull bar 220, when air or hydraulic fluid when pipeline 222 and 224 flows into, a distortion cylinder 126 just stretches out pull bar or withdraws.By form along arrow 226 the reciprocating motion of mark direction clockwise or rotate counterclockwise, a distortion air cylinder tie rod 220 should be connected with a distortion tooth bar 124 so that a distortion gear 124 fits in the rotation of forming roll tire 108.The rotation size of the elongation degree of pull bar 220 and a consequent distortion gear 124 is by 228 controls of a controlled distortion tooth bar brake.A controlled distortion tooth bar brake 228 is screw-threaded engagement with a distortion tooth bar brake seat 230, like this, can pass through the outside and inwardly motion of the rotation control brake device of tooth bar brake.

Figure 12 also shows one and is fixed on the indifferent equilibrium of distortion on the guide rod 134 and holds in both hands 232, and this handful is to be used under the control of a distortion lift cam 136, guarantees moving both vertically with to twist moving both vertically of caster bed 128 consistent of each guide rod 134.A distortion guide rod 134 can slide in the sleeve pipe on being fixed on upper guide plate 236 234, and upper guide plate is fixed on the framework 130.A distortion lift cam connecting rod 142 is connected with distortion caster bed 128 by U-shaped hook 283.The bottom surface ， And that U-shaped hook 283 is fixed on distortion caster bed 128 connects with a distortion lift cam connecting rod 142 at pivot 150 places.

The distortion head moves both vertically vibration absorber 238 as shown in figure 12.The vibration absorber 238 that moves both vertically is connected the lower end of guide rod 134, to slow down the landing of distortion caster bed 128.Practice shows, during coiling, the decline rapidly of distortion caster bed 128 produces impact loads to a distortion lift cam driven member 134, and this impact load is slowed down by the move both vertically effect of vibration absorber of distortion head.

The structure of a distortion sub-unit 104 sees Figure 13 for details.A distortion cylinder 126 and the fixed mount 240 that is fixed on the distortion caster bed 128 have been pointed out among the figure.On the distortion caster bed 128 elongated slot 242 is arranged, be used to place straight line bearing guide rail 244.The effect of straight line bearing guide rail 244 is that a guiding distortion tooth bar 122 moves reciprocatingly.The power transmission shaft 220 of a distortion cylinder 126 passes fixed mount 240 and is connected with tooth bar driving head 246.Boss 248 is arranged on the tooth bar driving head 246, and this boss passes the slit 250 of straight line bearing guide rail 244, and tooth bar driving head 246 usefulness screws 252 are fixed on the tooth bar 122.Tooth bar 122 is by tooth bar cover plate 245 and 256 location, and cover plate has a groove 258, for distortion headstock 274 provides assemblage gap.

For shown in Figure 13, distortion 116 has an a pair of distortion metal, and wire guider 260 and 262, guider 260 have a pair of for accepting axial slits or the guide groove 264 that primary cable designs.Guide groove 264 is parallel fully with feeding axis 119, but draws close slightly during by guider 260 at it, bifilar like this metal wire 112a and 112b at the port of export 120 by close proximity, And by bunchy be directed at format roll tire 108.A distortion metal wire guider 260,262 is connected together by a distortion axle sleeve 266.This axle sleeve encases guider 260 and 262 ， And are connected by the flange 268,270 on screw 272 and the guider 260 and 262.Distortion 116 is to be installed in the distortion headstock 274 with bearing 276, can move into to axis 119 and turn round.Pinion 124 is by the plane 284 and the screw 282 of keyway 280 and key 278 and distortion 116, is fixed in the distortion 116, and And and both are all on feeding axis 119.The orthogonal axe of feeding axis 119 and format roll tire 108.

Distortion caster bed 128 is connected with vertical guide stem 134 usefulness pivots 132, can pivot, and sees Figure 13 and 13a.Two supports 285 are fixed near slit 133 places, and guide rod passes this slit.Two fastener 287 penetrate warp-wise hole on the guide rod 134 and the mouth 289 on the support 285.Bolt tool 287 makes support 285 rotate around pivot 132 together with the distortion caster bed.

Can understand the fixing means of pressure roll arm 162 preferably referring to Figure 12 and 14, pressure roll arm 162 has a flange 164 that is placed between two pressure roll arm fixed mounts 286 and 288.U type fixed mount 286 and 288 is fixed with pressure roll arm axle bearing 166 and 168 respectively in the crook of U type.Two sides of U type are fixed on the framework 130 of a distortion guiding face 236 and low-voltage coil coil winding machine 100 firmly.Bearing pedestal 166 and 168 faces the flange 164 of pressure roll arm 162, the pressure roll arm is fixed on the vertical plane, but allow it to do to be parallel to the motion of vertical plane.

The configuration of each pressure roll and format roll tire 108 as shown in figure 15.Can see format roll tire 108 and the die cavity 110 that has primary cable 112 in the drawings.It should be noted that, in format roll tire 108 bottom sides, promptly with the correspondence position of toroidal transformer radially inner side 115 on, metal wire 112a becomes radially overlapping arrangement with 112b: in format roll tire top side, promptly with the correspondence position of toroidal transformer radial outside 117 on, metal wire becomes Zhou to put arrangement Xiang And.

Format roll tire 108 is fixed on the back of the body dull and stereotyped 290 by screw, and this back of the body flat board includes a radial flange 292, has outstanding slightly at the location-plate with the corresponding format roll tire 108 of flange.The back of the body dull and stereotyped 290 is fixed on the outer power transmission shaft 294 by a big nut 296 again.Outer power transmission shaft 294 is installed on bearing 298 and 300, can coiled forming roll tire axis 299 rotates And and motor or transmission device 301(Fig. 9) drive by a pair of input sprocket 297.Except that drive sprocket 297, outer power transmission shaft 294 also includes and is used for the strand wheel 304 that discharging chain wheels 302 and that driving pressure rolls compound cam 176 drive lift cam 136, the left side of bearing 300 is increment distortion transmission devices 306, and having the details of closing will narrate afterwards.

Be discussed as forming roll tire 108 now again, circle pressure roller 152 is configured in and relevant the giving on the allocation of format roll tire periphery.The periphery that circle pressure roller 152 is pressed in format roll tire 108 makes primary cable 112 in the distortion of the top of die cavity.This distortion is laterally finished by front side taper pressure roller 156, and this taper pressure roller is pressed in the front side of format roll tire and lead 112, causes horizontal (axially) deformation of the relative die cavity width of primary cable.Side pressure roller 156 is tapered, and the field of conjugate action moves with same speed on the every bit of path of contact between side pressure roller and the format roll tire like this.In addition, the truncation conehead of taper pressure roller 156 is positioned on the axis 299.Because the minimum speed that defines between the format roll tire field of conjugate action and the side pressure roller field of conjugate action is poor, the slip loss drops to minimum value.Must be noted that circle pressure roller 152 is between the flange 292 of the side pressure roller 156 and the back of the body dull and stereotyped 290.The back of the body dull and stereotyped 290 is to be supported by the rear side pressure roller 154 that is pressed in its back side.When front side pressure roller 156 is finished a forming operation, the axial moulding active force that rear side pressure roller 154 only produces with counteracting front side pressure roller 156 as reverse device.Based on above-cited same reason, rear side pressure roller 154 is also tapered.

As shown in figure 15, a left side holds roller 158 beaming roller 192 in abutting connection with format roll tire 108 periphery and the back of the body dull and stereotyped 290, and the flange 196 of beaming roller is clamped in metal wire 112a and 112b in the die cavity across format roll tire and the back of the body dull and stereotyped 290.For holding the flange 292 of the back of the body dull and stereotyped 290, beaming roller 192 provides a drop-center 293 of accepting flange 292.Because holding roller 158 and 160 does not provide forming operation, so the active force that they are added on format roll tire and the primary cable is limited.The side of this outward flange 196 and format roll tire and carry on the back not that the speed difference between the plate 290 can not form than lossy.

The installation of pressure roll as shown in figure 16, side pressure roller 154 and 156 is fixed on the side pressure roller rest pad 308, and rotatable.This rest pad is fixed on again on the side pressure roller fixed arm 310.Particularly side pressure roller fixed arm is at an inside bifurcated spare 312 that can hold rest pad 308.Rest pad 308 is fixed on the fixed arm 310 by fixture 314 and 316, and fixed arm is fixedly mounted on the framework 130 again successively, makes the side pressure roller be maintained fixed the position when the format roll tire rotates, but can be around its rotational.In view of this consideration, side pressure roller 156 must have enough height so that at the center, long limit of format roll tire 108 or diagonal when being in contact with it, and the side pressure roller can be meshed from minimum point to peak with the whole rotations of primary cable 112 the format roll tire.

Format roll tire 108, distortion 116, the various motions of circle pressure roller 152 and side pressure roller 156 and position relation are in proper order referring to Figure 17 to Figure 24.

Figure 17 and 17a have indicated that first coil begins the mutual alignment of respectively carrying out part when about 1/4th enclose from coiling.Should be noted that when first coil forming terminal Bei Fang Zhi And of lead 112 remains in the groove 114.As shown in figure 17, this moment, the format roll tire forwarded the position at roller tire first turning 318 clockwise to around its axis 299.318 places circle pressure roller 152 contacts with primary cable 112 at the turning.Figure 17 and 17a have illustrated two basic conditions of this winding process.

At first, the vertical center line of justifying horizontal contact wire between pressure roller 152 and the primary cable 112 or path of contact and side pressure roller 154 and 156 intersects.Vertical center line is again contact wire or the path of contact between side pressure roller 156 and the primary cable 112.Determine that above-mentioned position relation is in order to form a type window.This type window is positioned at the monobasic plane that level and vertical contact wire and cannelure 110 are limited.Like this, when primary cable 112 process type windows, just be constrained on top, bottom and the both sides of die cavity 110.Because the restriction of die cavity 110 and pressure roll 152 and 156 pairs of primary cables 112 is arranged, making has the moulding of the primary cable of different cross section to be achieved.If lead is not to be limited in the monobasic plane, binding side has not so just hindered the shaping of coil with the pressure of abated effect on binding side.

Secondly, primary cable 112 passes distortion 116 with linear along feeding axis 119 and enters the type window.This linear position relation can be by being determined at the inclination angle of pivot 132 by the height and the distortion head of the distortion of lift cam 136 and auxiliary lifting devices control 116.The inclination angle that should be noted that distortion 116 need not to be controlled, this be because when its when pivot 132 freely rotates, can select optimum angle of incidence voluntarily.The rising of distortion head is controlled the effect of its slave arm 140 and connecting rod 142 by cam 136.Because the geometrical construction of cam is used for on-demand system, so this linear position relation can not be kept always.

Because side pressure roller 154 and 156 is fixed in framework 130, then the motion of round pressure roller 152 is depended in all motions between circle pressure roller 152 and side pressure roller 154 and 156, promptly justifies the level of pressure roller 152 in plane, circle roller arm 162 place and moves both vertically.Specifically, when the rotation of format roll tire has produced variable radial displacement to the circle pressure roller, the motion of cam follower 186 in compound cam 176 grooves 182 causes the rotation of cam follower arm 174 around pivot 188 that move both vertically, slave arm 174 makes circle pressure roller 152 raise or reduction around the rotation of pivot 188, has so just kept the relevant position relation between circle pressure roller 152 and format roll tire 108.The horizontal movement of circle pressure roller is to form like this.The rotation of horizontal movement cam follower 180 motion in the guide groove 178 of compound cam 176 causing horizontal movement cam follower arm 172 around its pivot 184.This rotation causes the motion of horizontal movement connecting rod 170 again.The motion of connecting rod 170 causes that again pressure rolls the rotation of arm 162 around pivot 173, has so just finished the horizontal movement of round pressure roller 152.For admitting the turning 318 of format roll tire, the circle pressure roller moves to the maximum radial displacement from axis 299.When Figure 17 also was illustrated in the coiling operation of carrying out above-mentioned lead, circle pressure roller 152 was in the situation of the axis located lateral of side pressure roller 156.

When axis 299 rotated, distortion 116 turned position that move into to axis 119 were determined by pinion 124 and tooth bar 122 at format roll tire 108.Figure 17 has illustrated the typing situation of putting arrangement at 112 one-tenth And of coil 113 outsides, 117 place's leads with Figure 17 a, and the location situation of distortion 116 also has been described simultaneously to making lead become And to put the typing of row's example at 318 places, format roll tire 108 turnings.

Figure 18 has illustrated when the format roll tire and has clockwise rotated its turning 318 when having turned over vertical center line around axis 299, the mutual position relation between low-voltage coil reel winder 100 each parts.Should be noted that by lift cam 136 height of distortion head raises, the inclination angle diminishes, make that like this path of contact between distortion head and lead and the format roll tire keeps linear relation substantially.It shall yet further be noted that simultaneously round pressure roller and lead nibble with line be axis by side pressure roller 156.

Distortion head as shown in figure 18 moves into to axis 119 revolutions, has just surpassed the situation of vertical line.This single-revolution has twisted the metal wire of primary cable 112, makes at the side 319 of coil 113 outside 117(corresponding to the format roll tire) on become axle to be transformed into side 115(in coil corresponding to the side 321 of format roll tire to the metal wire that And puts arrangement) on overlapping arranged radially.For 320 places obtain 90 ° of torsion resistances at the turning, excessive distortion is necessary.Because distortion 116 is very little with distance between the turning 320, therefore excessive distortion that only need be very little is just passable.

Figure 19 and 19a show, when the format roll tire continues to clockwise rotate around axis 299, and the run location of second turning 320 each parts during near the circle pressure roller.Should be noted that whole conversions that metal wire 112a and 112b put the radially overlapping arrangement that is aligned to turning 320 from from 318 the Zhou at the turning to And occur in the short side of coil, the i.e. bottom side 315 of loop coil 113 and top side 317(Figure 10).The path of contact that will note 112 in circle pressure roller and lead simultaneously should be consistent with the axis of side pressure roller 156.This is to move right by justifying pressure roller 152, and as shown in figure 19, just finish a certain position behind the side pressure roll axis.It shall yet further be noted that distortion 116 a basic level that keep, make that promptly turning 320 provides a basic straight line to the contact point of lead 112 with format roll tire 108.Distortion this moment head does not rotate around feed line 119, as Figure 18 and shown in Figure 19.

Shown in Figure 20, be the situation that the coiling operation continues.By means of circle pressure roller and side pressure roller 152 and 156 and primary cable 112 between the formed type window of path of contact, primary cable 322 is moved from the turning along the side 321 of format roll tire, formed the radial outside 115 of coil 113.In this stage of winding process, the metal wire 112a of primary cable and 112b are provided necessary cake formula structure by radially overlapping for forming the annular low pressure winding.Especially it should be noted that, distortion 116 this moment dropped to be lower than roller tire axis 299 position 323(shown in dotted line position among Figure 17), And begins upwards to rotate around pivot, with the linear relation that keeps with the type window that is formed by circle pressure roller 152 and side pressure roller 156.In addition, circle pressure roller opposite side pressure roller moves down forward, so that the type window is remained in the monobasic plane of side pressure roller center line.Like this, when the center of format roll tire 108 sides 321 near circle pressure roller 152 and turning 320, when leaving round pressure roller 152, circle pressure roller 152 is in the location, front of side pressure roller 156 axis.In Figure 19～20, distortion 116 does not move into to axis 119 and rotates.

The continuation of above-mentioned coiling operation and pressure roll 152 and 156 are in the location corresponding to 321 centers, limit, format roll sidewall in the toroidal transformer coil outside 115, as shown in figure 21.It should be noted that, this moment distortion 116 slightly pivots near horizontal level Xiang Shang Yi And.But, in Figure 20 and Figure 21, distortion 116 does not move into to axis 119 and rotates.Circle nip drum 152 continues to move on to the radial position near roller tire axis 299 minimums downwards, and slightly is partial to the right side of side pressure roller 156 axis.

In Figure 22, the format roll tire continues to rotate to finish the moulding of coil inboard around iron core axis 299.When rose at turning 322, the distortion head also rose, but pivots simultaneously, to keep a level of approximation state.Shown in Figure 21-22, the distortion head does not move into to axis 119 and rotates.In Figure 22, for adapting to the inclination angle of side 321, circle pressure roller 152 opposite side pressure roller 156 moves right, so that keep the path of contact of circle pressure roller 152 and primary cable 112 on the center line of side pressure roller 156.Like this, when round pressure roller was left near the center of circle pressure roller 152 and side 321 in turning 322, circle pressure roller 152 was in the axial location above side pressure roller 156.

Be the situation that 108 continuation of format roll tire clockwise rotate around its axis 299 as shown in figure 23.Put arrangement by the outside 117 desired axles that radially overlapping arrangement changes ring coil 113 into to And for adapting to lead, the distortion head clockwise rotates along the feeding axis and slightly surpasses 90 ° of angles to form distortion.Designing this, to cross distortion be for making next turning, i.e. the abundant leads 112 of engagement horizontal arrangement in turning 324.It should be noted that the distortion size has an angular range with respect to horizontal line, for example desirable 20 °-30 ° when the metal wire 112a of the primary cable 112 of horizontal positioned and 112b are twisted.Owing to have the gap between the turning 324 of distortion 116 and format roll tire 108, also because the distortion of metal wire is to carry out with twisting between the output 120 at the turning 322 of format roll tire 108, therefore can utilize the gap between format roll tire 108 and the turning 324 to make a distortion inordinate rotation, when the format roll tire clockwise rotated, primary cable 112 became horizontal positioned at format roll tire turning 324 with the meet place of lead like this.For cooperating turning 322 and high moving of putting, circle pressure roller 152 has been Shenged And near its maximum height, and the axis of opposite side pressure roller 156 has moved and moved to left simultaneously, so that the type window is remained on the axis of side pressure roller.Meanwhile, distortion head rises to its maximum height ， And and is in the horizontal orientation state fully.

Figure 24 is the last performance of the complete coil 113 of low pressure winding.The metal wire 112a of primary cable 112 and 112b Zhou put the outside 117 of arrangement as the toroidal transformer winding Xiang And.At this moment, the below ， And that the distortion head has moved to axis 299 begins upwards to rotate around pivot, so that keep the line of collimation state with format roll tire 108 planes 319.Circle pressure roller 152 moves to left and remains on the axis of side pressure roller 156 with the path of contact with itself and lead 112.To shown in Figure 24, in said process, distortion 116 does not move into to axis 119 rotates as Figure 23.Before 113 coilings of first coil were finished, the end of primary cable 112 left groove 114 And and is placed in the outside of side pressure roller 156, so that continue the coiling of coil.

As Figure 17-shown in Figure 24, a left side holds roller 158 and the right roller 160 that holds is located in type coil 113 with the shape action ， And of format roll tire 108 on die cavity 110.When holding roller 158 and 160 not controlled action as yet, at next vertical compressions of effect of its gas receiver 204 and 214 on format roll tire 108.

As mentioned above, the type window of justifying the monobasic plane that is positioned at side pressure roller 156 axis that pressure roller 152 and side pressure roller 156 and format roll tire 108 form meets moulding and requires.The Dan And inaccuracy because the restriction of mechanical cam structure, this type window can meet the requirements.Can consider like this to replace cam 136 and 176, make round pressure roller 152 be able to accurate location, so that on plane, side pressure roller 156 axis place, provide required type window with the control motor.So also just need not to have considered the matching problem of mechanical cam, this design concept has been included in the scope of claim of the present invention.

Figure 10 shows several in type low pressure winding coils 113.It should be noted that, winding is bifilar (being made up of metal wire 112a and 112b), be characterized in overlapping at the radially inner side 115 lead warp-wises of coil, axial And puts at radial outside 117 leads, and the radially overlapping and transformation of axle between And puts is to carry out on the top 317 of coil or bottom 315.Because this transformation is limited in the top and the bottom of winding, makes the gap factor of coil be improved, bifilar distortion coil is achieved the overlapping of top and bottom.In addition, shown in Figure 10 a, the cake formula structure of coil 113 is no matter from only being to be similar to from observation down still.This cake formula structure can the corresponding increase by the forming force that provided by circle pressure roller 152 and side pressure roller 156 is provided.Give under the insulation situation at lead 112, should select suitable pressure, under the situation that does not influence the insulating barrier insulation quality, the distortion of pilot.Because insulating barrier has to a certain degree elasticity and tension stress, therefore can suitably increase distortion.Do not give under the insulation situation at lead, distortion can fully increase to form desirable cake formula structure.

The working width of side pressure roller 156 can peel off formed coil 113 effectively from format roll tire 108.When being peeled off, form wire circle 113 is spring-like, as shown in figure 25.When continuously winding is used for the moulding of toroidal transformer at last, the coil shape of being pressed or adjoin each other.

It is extremely shown in Figure 26 as Figure 25 that primary cable coil winding machine 100 the 4th sub-unit is stored roller tire sub-unit 326.This sub-unit comprises that first stores the roller tire 328 and the second storage roller tire 330.First stores the roller tire an input end cap 332.This end cap is connected by shaft coupling 334, along with format roll tire and outer power transmission shaft 294 rotate together.First stores the roller tire also has an output end cap 336, and this end cap inner bearing 340 is installed on the support column 338.The width of support column 338 is less than the spacing of two shaping low-voltage coils 113.First stores the roller tire has four prisms 342 to be fixed between input end cap and the output end cap, makes the supporting structure that forms a square-section be used for supporting the coil 113 that has wound.When outer power transmission shaft 294 rotated, format roll tire 108 and second was stored the 328 corresponding rotations of roller tire.Be wound into the disc coil 113 in four directions on the format roll tire when lead 112 after, side pressure roller 156 constantly peels off coil and is rotating on the corresponding to storage roller tire 328 with the format roll tire.

Second stores roller tire 330 an input end cap 346, and this end cap is fixed with dog screw 350 and key, and this input end cap is fixed on again on the intermediate solid drive shaft 348 simultaneously.Intermediate solid drive shaft through first store between roller tire 328 and the format roll tire 108 And and outside power transmission shaft 294 coaxial lines.Sleeve pipe 349 is configured in first and stores between roller tire output end cap 336 and the intermediate solid drive shaft, is used for intermediate solid drive shaft 348 is bearing in support column 338.Second stores roller tire 330 an output end cap 352, and this end cap is fixed on the intermediate solid drive shaft 348 by dog screw 354 and key.Second stores roller also four prisms 356, and these four prisms are fixed between input end cap 346 and the output end cap 352, make the supporting structure that forms a square-section be used for supporting the coil 113 that has wound.Should be noted that the second storage roller tire 330 is suspended on the external support post 338, the easy like this coil that will be shaped 113 is stored roller tire 330 from second and is taken off.

The form-wound coil 113 of primary cable 112 is stored the gap that roller tire 338 passes vertical support column 338 once leaving first, drops on second and stores on the roller tire 330.First length of storing the roller tire 328 and the second storage roller tire 330 will be enough to hold the complete shaping coil of wire 113 parts of toroidal transformer low pressure winding.

Facts have proved that lead is after format roll tire 108 is bent, because the natural elasticity of conductor material, the forming angle at formed coil 113 turnings is slightly larger than 90 °.Consequently, four corner angle summations of formed coil are greater than 360 °.In other words, because each turning is not bent to positive an angle of 90 degrees, so form-wound coil is not desirable coil.When if angular displacement appears in four turning sums of low-voltage coil 113 and 360 °, then four of primary cable turnings should be in not that restrained condition is compensated on a horizontal axis.Because four turning sums of each coil are greater than 360 °,, make four corner angle sums and 360 ° angular displacement occur, so the coil turning is scroll under nature promptly because each turning all accumulates the angular displacement that closes on the turning.

Cause coil to be the crooked not enough of nature spiral form, can be remedied by compound storage roller tire, as Figure 25, compound storage roller tire sub-unit 326 is a kind of crooked excessively devices, in order to accepting crooked not enough coil 113 from format roll tire 108, with mistake around method come the compensated bend deficiency.Second store roller tire 330 can relative first store roller tire 328 periodically inordinate rotation make the turning of coil 113 near 90 ° to form addition bend to form-wound coil 113.Overbending is to be in not restrained condition at coil, takes place during relative horizontal axis location, its turning.This overbending when three coils 358,360 and 362 first store roller tire 328 and the second storage roller tire 330 from 0～180 ° by dextrorotation then finish.Because the coil 113 of primary cable is to be constrained on first to store on four prisms 342 of roller tire 328, similarly, at second coil 113 of storing the primary cable on the roller tire 330 also is to be constrained on four prisms 356, therefore, it is to act on three independently not have on the constraint coils 358,360 and 362 that the second storage roller tire, the 330 relative first storage roller tires 328 are crossed bending motion.Act on the overbending on coil 358,360 and 362, remedied the elastic recoil and the crooked deficiency that occur in format roll tire 108.Second stores 330 pairs first inordinate rotation of storing roller tire 328 of roller tire, is controlled at format roll tire revolution by mechanical device and begins after moving three weeks.All there is the coil 358,360 and 362 of three moulding deficiencies to be able to brake forming so each time.The neither one coil must carry out the overbending moulding second time.

Be fixed on the intermediate solid drive shaft 348 because second stores roller tire 330, so it can be to first inordinate rotation of storing 0～180 ° in roller tire 326 works.Intermediate solid drive shaft 348 can be by making 0～180 ° independent rotation as Figure 15, Figure 27 with the relative outer power transmission shaft 294 of device shown in Figure 28.Unless should be noted that intermediate solid drive shaft 348 rotates with outer power transmission shaft 294 generally speaking in order to do 0～180 ° of excessively transhipment.

Shown in Figure 15,27 and 28, outer power transmission shaft 294 can be connected with the outer additional power transmission shaft 364 of its rotation with one.Intermediate solid drive shaft 348 extends to outer power transmission shaft 294 and outer additional shaft 364 always.Intermediate solid drive shaft 348 and outside prepare one between the additional shaft 364 coaxially and cross distortion linear cam 366.This cam 366 is fixed on outer additional shaft 364 inboard ， And and uses the key pin 368 that matches with axial groove 369 on the cam to cooperate with outer additional shaft, rotates with outer additional shaft.Because key pin makes cam 366 to do axial motion by external mutually additional shaft 364 with the cooperation of axial groove.Intermediate solid drive shaft 348 has a key pin 370, and this key matches with the cam path of linear cam 366.Axial groove on the cam 366 is by cam angle surface 372 and cam axial surface 374 formed V-shaped grooves.

Examine Figure 29 a, 29b and 29c, can find that distortion cam 366 made key pin 370 be pressed against on the cam angle surface 372 for intermediate solid drive shaft 348 and the axial motion to the right of outer additional shaft 364, And moves up and causes intermediate solid drive shaft 348 the clockwise rotating of external additional shaft 364 (from the right) mutually.When moving to right of cam 366 finished, key pin 370 contacted with mistake distortion cam 366 axial vane surfaces.When the relative intermediate solid drive shafts 348 of cam 366 and outside additional shaft 366 when returning left, crossed the meander coil location because intermediate solid drive shaft resides in to store on the roller tire 330, key pin 370 near axial cam plane 374 maintenance its by the position that clockwise rotates.In other words, the V-type cam path can allow 0～180 ° lost motion according to the size of " V " type angle.As shown in the figure, V-type is protruding in providing about 50～60 ° of angles of rotation for well.When the continuous Zhuan Dong And of inside and outside power transmission shaft 348 and 294 Ji is wound on all the other coils 113 of storing on the roller tire, cross meander coil and move to the second storage roller tire 330, not crossing meander coil is moved to first and stores roller tire 328 and second and store that ， And causes that the second storage roller tire rotates counterclockwise between the roller tire 330.This rotates counterclockwise after key pin 370 is got back to cam angle surface 372 and just finishes.Have this moment three to cross meander coil and reside in first and store between the roller tire again, these three coils again the right side by cam 366 by crooked excessively.This process repeats once after per three coils are crossed bending, crosses meander coil 113 afterwards and slides to the second storage roller tire 330 continuously.Situation when Figure 30 illustrates this and crosses winding process and finish.

The device that makes relative intermediate solid drive shafts 348 motions of cam 366 as shown in figure 27.Two cylinder supports 376 are fixed on the main frame 130 of low-voltage coil coil winding machine 100.Support 376 has a pair of appearance to receive the fixedly vertical fitting flange 378 of cylinder 380 of And.Each cylinder 380 has a control to hold in both hands 382, and this control handful is passed circular hole 384 And on the flange 378 and recommended cranse parts 386 at circular hole 388 and and link to each other.The rigid bearing that recommending cranse 386 has a central shaft bearing 390 and to be used to hold with rigid bearing 394 covers 392.Bearing 394 can hold cam 366 And and be rotatably assorted with it.Axle sleeve 395 is fixed on the cam end 396, so just cam 366 is fixed on and recommends on the cranse 386.

As shown in figure 15, when cylinder 380 stretches out, recommend cranse 386 and be in 397 target positions of dotted line.Simultaneously cam 366 returns to the position shown in Figure 29 a and the 29b, when cylinder 380 withdrawals, recommends cranse 386 and moves to right and get back to solid line institute cursor position among Figure 15.Meanwhile, cam 366 also moves right, and shown in Figure 29 a, causes key pin 370 to move along cam edged surface 372, and the outer relatively power transmission shaft 294 of intermediate solid drive shaft 348 is clockwise rotated.This rotation causes that second stores clockwise rotating of the roller tire 330 relative first storage roller tires 328, makes and must be bending at two three coils 358,360 and 362 of storing between the roller tires.In sum, Addon Volume is around having compensated all turning accurate formings that coiling Bu Zu And makes formed coil 113.

Recommend cranse 386 when moving to left when cylinder 380 stretches out to make, move to left the position shown in dotted line among Figure 15 397, owing to cross the effect of controlling of meander coil 113, intermediate solid drive shaft 348 keeps the former position that clockwise rotates, so that key pin 370 is reverted on the cam edged surface 372.

As mentioned above, in case three coils are arranged after moulding on the format roll tire 108, second stores roller tire 330 begins to clockwise rotate in 0～180 ° of scope with regard to the relative first storage roller tire.For ease of the counting of formed coil 113 on format roll tire 108, outer additional shaft 364 is furnished with the axle sleeve 398 of two band boss 399, and the counting device that axle sleeve and can write down outer additional shaft 364 and shaping axle revolution is meshed.Outer additional shaft 364 revolutions three circles, a signal (method that produces signal does not provide) just appears in counter, stretching out and shrinking of this signal controlling cylinder 380 makes the second storage roller tire 328 relative first store roller tires 330 and clockwise rotates in 0～180 ° of scope.Although the above-mentioned bending apparatus of crossing is the coiling that is used for cake formula square coil with method, with quadrat method also applicable to the coiling of the directional coil of being correlated with.In a word, any above-mentioned application of crossing bending apparatus and method all belongs to the scope of claim of the present invention.

Figure 31 a to 31c illustrates the concrete device of another bifilar primary cable 301.Shown in Figure 31 a, it is little trapezoidal shape wired conductors 303a and big trapezoidal shape wired conductors 303b that bifilar winding 301 has the cross section, and these two leads are put arrangement in the overlapping footpath that is arranged in of the radially inner side of coil to outer side And.Should be noted that form at radially inner side lead 303a and 303b one trapezoidal, at radial outside or parallelogram.The combination distortion target seeker 309 of coil by shown in Figure 31 b and 31c is by the Wire-wound moulding that continues of the company shown in Figure 31 a.Should be noted that the distortion head has the fixedly target seeker 305 of the big trapezoidal shape wired conductors of a feeding and the rotation target seeker 307 of the little trapezoidal shape wired conductors of a feeding.There is a target seeker that moulding guiding channel its trapezoidal shape wired conductors that closely cooperates is arranged.Rotate target seeker 307 and can clockwise or rotate counterclockwise 180 °, to be formed on the location of Figure 31 b and 31c.

Make lead 303a and 303b enter the device of shaping position as shown in figure 31 shown in Figure 31 d and 31e.This device comprises outside guiding roller tire 311a and 311b, and this side guiding roller is vertical space reference axis and orientation in relative rotation.The guiding roller stretches out by arrow 313a and 313b indicated direction or bounces back.Guiding roller in the outside stretches out along the direction of arrow during moulding of the annular low pressure lead loop outside in abutting connection be positioned ， And and be in position shown in Figure 31 b rotating target seeker 307 of a rectangular cross section core body.The engagement of outside guiding roller and lead 303a and 303b is put the outside Huo And of coil 301 and is arranged typing.After coil outside moulding, outside guiding roller resets along the direction of arrow.After the moulding of coil top side, lead can rotate target seeker and turn clockwise 180 ° when reorientate shown in Figure 31 c.

When the inboard moulding of annular base pressure coil 301, be positioned at a couple who receives on the reference axis in the space and guide roller 315a and 315b, move inward along arrow 317a and 317b indicated direction, be meshed with lead 303a and 303b, shown in Figure 31 e.When the inboard moulding of coil 301, inboard guiding roller 315a and 315b are with the stacked arrangement typing of lead, shown in Figure 31 e.Afterwards, when the moulding of coil bottom side, rotate guiding roller 307 and rotate counterclockwise, just withdrawal of inboard guiding roller 315a and 315b.This process is repeated to coil molding continuously and finishes.

The concrete device of another bifilar low pressure winding 331 is shown in Figure 32 a-32e.Winding 331 comprises inboard twin conductor 323a and 323b and outside twin conductor 325a and the 325b that is made by continuous conductors.Lead 323 and 325 is separated by the insulating trip 327 of a coiling.A chi of lead 323 and 325 square-section is zhang greater than vertical dimension.Lead is vertically arranged at the radially inner side of 323,325 windings, Jing Xiang Wai Ce And shoulder arrange.In other words, the high cross section of each lead is placed on the radially inner side of winding.Low cross section is placed on the winding radial outside.

Lead 323 and 325 turns to the structure shown in Figure 32 a by the distortion shown in Figure 32 b and the 32c 329.Distortion 329 clockwise rotates 90 ° to position shown in Figure 32 c from position shown in Figure 32 b, then rotates counterclockwise 90 ° of positions of getting back to 32b.A lead distortion interior guiding channel guiding, relative its rotating shaft of distortion head and the right turning of lead are positioned.When lead 323 and 325 is delivered to the live-rollers tire 333 of quadrangular section by the distortion of the orientation shown in Figure 32 b and 32c head, promptly suitably located, shown in Figure 32 a.Referring to Figure 32 b and 32d, there is shown lead in the location of winding radial outside situation, put arrangement by circle roller 335 leads with low cross section Cheng And as we can see from the figure.Can see that in Figure 23 c and 32e because distortion head turns clockwise 90 °, shown in Figure 32 b, Zai Bei And of lead puts and arrange the location, but occur with the form of the high cross sectional arrangements that is fit to the moulding of winding radially inner side.The rotation of distortion 329 occurs in the inboard of Circular Winding and the outside on roller tire 333 after the moulding, and the conversion that makes lead 323 put arrangement from overlapping Pai Lie to And like this occurs in the top side and the bottom side of Circular Winding.Certainly by lead 323a and 323b around to the interior annular coil will be prior to coiling by the outer coil of lead 325a and 325b.Behind the inner coil coiled, insulating trip 327 can be on inner coil.Owing to used insulating trip, inner coil can be connected on 120 volts of voltage circuits of 120/240 volt of dual output power supply, outer coil can pick out another 120 volts of voltage circuit ， And is distributed these two voltage circuits in the transformer magnetic core.

The concrete device of another of low-voltage coil, be to use the coil of forming by five continuous round conductors, lead is by a guiding And alinement orientation, and the coiling of this low-voltage coil is to have turning round on the shape framework of quadrangular section to carry out one, and the structure of this coil is.There are every group of 5 leads to lead line And for several groups at the coil radial outside and put arrangement, in two groups of overlapping arrangements of lead of radially inner side of coil.Winding process is by two groups of Dao Zu And of 5 every group that collect on loop coil top side and the bottom side lap position that it causes the loop coil radially inner side to be finished.This process is up to just finishing behind intact whole 120 hint circles.Insulating trip is around the top in first volt of 120 volts of district, the top in the 2 120 volt of district also will around on insulating trip.In this concrete device, use 5 No. 13 insulation circle copper conductors.In a word, the lead number, conductor material, wire shape, wire gauge can be selected by the designer.In addition, as long as loop coil can provide bigger comprehensive thick change and width, the number of insulating trip just can change on the loop coil inboard and the outside.

Should be noted in the discussion above that the radical that there is no need to limit each winding wire of primary cable winding, and the aligning method of the given shape of lead or disc coil lead.

Being described as follows of high-tension coil coil winding machine.

As shown in figure 33, high-tension coil coil winding machine 400 comprises a computer numerical control device 402 and a coil winding machine 404.The MarK Century 2000 Mc CNC type controllers that digital control implement 402 can use Ohio, USA thirty Cincinnati General Electric Co. Limited to produce, the control cable terminal box 406 on these digital control implement 402 coil winding machines 404 are to connect with a control cable 405.Digital control implement 402 is passed to control bobbin winoler 404 with the signal of various functions by cable 408, and this will be elucidated later herein below.Coil winding machine 404 mainly contains two parts, i.e. revolving roll tire parts 410 and a lead positioning element 412.The lead positioning element can make lead accurately locate on the roller tire when the roller tire turns round, and lead 412 just can draw the high-tension coil or the winding 413 of several whole connections by giving fixed shape on the roller tire.In front view (Fig. 2), pitch of the laps 413 is wedge-type or cake formula, and in end view (Fig. 3), coil is common square-section.Rotating roller tire parts 410 comprise a tyre assembly 414, and this assembly makes lead 416 coileds give fixed shape, the cake formula high-tension coil 413 that is all connected around 417 revolutions of roller tire axis.

Roller tire assembly 414 has a forming rolls tire, and roller tire axle 418 makes this roller tire around axis 417 revolutions.Between axle 418 and roller tire assembly 414, play transmission at roller tire retainer (not having diagram).Roller tire axle 418 is to support with left roller tire bearing 422 and right roller tire bearing 424, can turn round.By speed reduction gearing 428 and roller tire shaft transmission belt wheel 430 rotation is reached roller tire axle 418 with clothes motor 426.Roller tire axle 418 drives roller tire positioning cam 432 revolutions that are contained in its left end simultaneously, and the engagement of the roller follower of this cam rollers tire position-sensing switch 434 is to coordinate mutually.A ratchet 436 is arranged on positioning cam 432.It can with the roller of position-sensing switch 434 bridle joint mutually, this is used for indicating locating of when the axis of measuring roller tire assembly 414 this roller tire assembly.This will describe in detail below.

Roller tire assembly 414 has a tetragonal roller sicula 438, as the central support pieces of roller tire assembly 414.Coil sides template 440 is wedge-like plates, and every block of plate all has a cubic hole roller sicula 438 can be put into.These wedge-like plates are along radially being installed on the pipe 438 of axis 417.These coil side templates 440 are thrown apparent time when top or bottom (along direction shown in the arrow 441) from high-tension coil 413, are wedge-like or plate-like.Should be noted that each coil sides template 440 has lead to hand over around guide finger 444, this pin is fixed on the edge of side template near the top of high-tension coil and outside switching place.Template 442 has an identical cubic hole in the coil, and they are inserted between the coil sides template 440, is used to make coil sides template 440 to be positioned evenly over pipe 438.Just the cheese with coil sides template 440 is opposite to be noted that the cheese of template 442 in the coil.The cheese of template 442 depends on high-tension coil 413 desired cheeses in coil sides template 440 and the coil.As shown in Figure 2, cake formula high-tension coil 413 is narrow at its radially inner side 443.For the shape of the radially inner side 443 that constitutes cake formula high-tension coil 413, at inner face 445 places of cheese, template 442 has less axial thick change in the coil, and coil sides template 440 has bigger axial width.Template 442 in the coil, inner face 445 places in the plate-like part also have bigger height from the top to the bottom, make this shape can adapt to the trapezoidal together with the insulating case 50 that is added of primary cable usually.Coil sides template 440 has the bigger degree of depth at inner face 445 places of pie part, has adapted to coil 413 and have bigger radial thickness on its narrowest axial point.Template 442 and two adjacent windings side template 440 are installed on the roller sicula 438 in each coil, form a die cavity that holds lead 416 coils.

During assembling roller tire parts 414, alternately template 442 in coil sides template 440 and the coil is contained on the pipe 438, makes them nestle up left coil template anchor clamps 446.Right coil form board clamp 448 is fixed on the pipe 438 when template 442 in coil sides template 440 and the coil is contained in pipe 438 Shang ， And tightly, template 440 in coil sides template 440 and the coil is clamped in as shown in figure 33 position with trip bolt 450.Being noted that a part of roller tire parts 414 are broken away in Figure 33, is in order to see clearly easily.

As mentioned above, the rotation of roller tire parts 414 is to be driven by the retainer that is installed on the pipe 438 left end supports.The right-hand member of roller tire parts 414 is to borrow the support 452 that is fixed on pipe 438 right-hand members to support.Support 452 has a center, and this is used for top 454 bridle joint of tailstock assembly 456.Roller tire parts 410 are installed on the frame assembly 458, and this frame assembly has square 460 and bearing 422 and 424 being used for supporting servo motor 426, and frame assembly 458 also has a main part 462, is used for support wires positioning element 412 and tailstock 456.

Metal wire positioning element 412 contains a servomotor 464, this motor borrows motor cabinet 468 to be installed on the left column 466, servomotor 464 drives the leading screw 470 that has regulation spiral shell square, this leading screw be installed in 466 and right column 472 between.Leading screw relies on left bearing 474 and right bearing (not having diagram) to support.Guiding feed rod 478 is positioned at above the leading screw 470, and and Zhi Pinghang, it is installed between left column 466 and the right column 472.

Moving seat 480 borrows last sliding bearing 482 and guiding feed rod 478 to be slidingly connected.Move seat 480 and also have a transmission ball nut 484, its pitch is consistent with the pitch of leading screw 470, and servomotor 464 makes leading screw 470 revolutions, thereby nut 484 moves to the left or to the right, moves seat 480 and also correspondingly moves to the left or to the right.Being noted that in the lower end of moving seat 480 has a sliding bearing 532, and it is connected with the guiding feed rod 534 that moves seat 480 and guiding for supporting.Under the feed rod 534 that leads be bearing on left column 466 and the right column 472, as shown in the figure, And and be parallel to leading screw 470 and last guiding feed rod 478.

Move the bearing housing 486 that seat 480 has a tilt axis, this case drives inclined shaft 488 revolutions, and inclined shaft is driven by servomotor 490.A lift cam auxiliary body 494 is arranged on inclined shaft 488, be contained on the bearing, can turn round around inclined shaft.On inclined shaft 488, also fixed one with oblique axis 497 rotating castor arms 496, as shown.

Can know by Figure 33 a and to find out that the bearing 500 on castor arm 496 has connected one can rotating metal wire locating wheel york piece 498.Metal wire locating wheel york piece 498 can be around axis 568 revolutions by castor bearing 500 centers, and this axis and oblique axis 497 and roller tire axis 417 meet at right angles.Metal wire locating wheel york piece 498 is divided into two conductive arms 502, and this two arm is used to install the axle of metal wire locating wheel 504.The axle of metal wire locating wheel 504.Metal wire locating wheel 504 is installed in that (be orthogonal to axis 568 and oblique axis 497, relatively metal locating wheel york piece 498 is done on the rotating bearing around axis.One groove 506 is arranged on the wheel rim of metal wire locating wheel 504, and this groove is used for guide wire 416 to die cavity.Also have a metal wire saddle 508 on the castor arm 496, front jocket wheel 510 and back guide wheel 512 are housed on the frame.Front jocket wheel 510 and back guide wheel 512 are contained on the lead saddle 508 separately, and can rotate ， And and each guide wheel has a groove for guide wire 416 usefulness on wheel rim.Utilize a suitable spring (not having diagram) to make upwards deflection of metal wire guide wheel 508, be with upwards deflection of guide wheel 510, metal wire 406 just is tensioned.Also has a guide block 514 and a guide block 516 that is fixed on the back that is fixed on the front on the castor arm 496, guide block 516 causes back guide wheel 512 with metal wire 416 below castor arm 496, then, after metal wire 416 passes back guide wheel 512, forward to front jocket wheel 510.Metal wire 416 passes guide wheel 510, downwards passes guide block 514 again and in the groove 506 on metal wire guide wheel 504 wheel rims that arrive, makes metal wire accurately on roller tire parts 414, and this will describe in detail in Figure 35 to Figure 38.

Also have a lower tumbler frame 536 in the bottom of moving sliding base 480, lower tumbler 538 is arranged on the frame.Metal wire tensioning wheel carrier 540 is installed on the right column 472, and a regulating wheel 542 is arranged on the frame.Regulating wheel 542 and lower tumbler 538 are sent into metal wire 416 in the metal wire positioning element 412.Metal wire 416 from lower tumbler 538 be upward through the back guide block 516, then from the above mentioned to lead locating wheel 504.When metal wire was on roller tire parts 414, nationality helped spring loaded and obtains Necessary Tensility metal wire regulating wheel 542 at metal wire regulating wheel 542.

As mentioned above, inclined shaft bearing housing 486 is to link to each other with moving sliding base 480, but is not fastenedly connected.Exactly, bearing housing is that a bolster (do not have diagram) is loaded onto, can be around Z one axis 518(Figure 33) rotate.Inclined shaft bearing housing 486 rotates relative to Z one axis 518, can make inclined shaft 488 make corresponding inclination ， And and make metal wire locating wheel 504 move up and down (direction of pressing arrow 520).

Moving up and down of the banking motion of inclined shaft bearing housing 486 and metal wire locating wheel 504 realized by lift cam parts 522.As shown in figure 33, lift cam parts 522 contain a lift cam servomotor 524, this motor cam 528 and 494 engagements of lift cam servicing unit, when lift cam 528 during in servomotor 524 control turning down, the gabarit of cam moves up and down lift cam servicing unit 494 and inclined shaft bearing housing 486 is tilted.Should be noted that in Figure 33 inclined shaft bearing housing 486 and metal wire locating wheel 504 are acclivitous fully aware ofly.Lift cam parts 522 are installed on the lift cam frame 530, and this is anchored on moving sliding base 480 ， And and does side-to-side movement in the control of servomotor 464 and digital control implement 402 with moving sliding base 480.

Also have a roller fetal position measurement mechanism 543 on the lift cam frame 530, this device contains 544 and probe sensors 546 of a probe.Probe sensor 546 is installed on the support of lift cam frame 530, is movably.Probe sensor 546 can not made stretching motion towards support 548 by an air cylinder device (having diagram).Roller fetal position measurement mechanism 543 is connected with computer numerical control device 402, usually be used for the axial location And at template 440 edges in each coils of measuring roller tire parts 414 and position data is passed to computer numerical control device 402, like this, when coiling, can make metal wire locating wheel 504 between each coil sides template, accurate position be arranged again.

Shall also be noted that servomotor 524 is high-precision devices, is to handle according to the control signal that computer numerical control device 402 sends.Computer numerical control (CNC) device 402 makes each watch strand motor and finishes effect described below mutually in phase.

In the operating process of high-tension coil coil winding machine 400, the roller tire parts 414 of sky are installed between the retainer and tailstock assembly 456 of roller tire sub-unit 404.Because when production environment mesohigh coil winding machine rotates, the several roller tire parts 414 that use are continuous, and because coil winding machine 400 generally will produce foozle, the size of each roller tire parts 414 each part can be slightly different, so the gross accumulation error of coil sides template 440 and interior template 442 closed assemblies has just changed the length of roller tire parts 414 widely.Therefore, the metal wire 416 in the die cavity is accurately located easily, just must measure the position of each coil sides template 440 of roller tire parts 414.This measuring process is finished by roller fetal position measurement mechanism 543, and it illustrates shown in Figure 34 and Figure 34 a.

In order to simplify the measuring process of roller tire parts 414, to forward roller tire axle 418 to original position, the roller that is roller tire position-sensing switch 434 is meshed with the ratchet 436 of roller tire positioning cam 432, and at this moment, the physical location of roller tire parts 414 is the positions 550 of painting with broken broken line as among Figure 34.When roller tire parts 414 during in position 550, a gap is arranged between roller tire parts 414 and probe sensor 546, be used for servomotor moving sliding base 480 and attached roller fetal position measurement mechanism 543 are moved to roller tire parts 414.

When carrying out the die cavity of axial measuring roller tire parts 414, dependence servomotor 464 moves to roller fetal position measurement mechanism 543 near the first metal wire die cavity.Roller tire parts 414 are in position 550 at this moment, provide a gap to probe sensor.One when probe sensor 546 is in suitable position, and roller member 414 554 turns over about 90 ° towards the measuring position, with coil sides template 440 face the wall and meditate or sidewall near outside turning, footpath, shown in Figure 34 and Figure 34 a.When roller tire parts 414 are in measuring position 554, servomotor begins revolution, until probe sensor 546 is read the sidewall that this plate of metal wire side template 440(constitutes the metal wire die cavity), roller fetal position measurement mechanism 543 has just accurately determined the position of facing the wall and meditating of coil sides template 440 like this.Exactly, probe sensor 546 is that an application contact comes the contact pickup to coil sides template 440 readings.When probe sensor 546 sense coil side templates 440, the axial value of metal wire die cavity equals the position of servomotor 464.Computer numerical control device 402 deposits this value in.Obtain after this value, roller tire parts 414 forward probe～interstitial site 550 again to, borrow the revolution of servomotor 464, and roller fetal position measurement mechanism 543 is moved to next metal wire die cavity, then, forward roller tire parts 414 to measuring position 554 again.The value And that so just obtains second die cavity respective side surface is stored in this value in the computer numerical control device 402, each metal wire die cavity is repeated the process of this measurement-mobile-measurement, all measuring reading ， And until each metal wire die cavity respective surfaces of whole roller tire parts 414 is recorded in the computer numerical control device.These values be after when winding the line process, be used to control the revolution of servomotor 464, make 504 pairs of metal wire die cavities of metal wire locating wheel that accurate localization be arranged.

During coiling, lead is placed in the die cavity that is made of side template 440 and interior template 442 its mode as shown in Figure 35 to Figure 38.As mentioned above, the effect of metal wire locating wheel 504 is locating guiders that a metal wire 416 is put into the metal wire die cavity.Shown in Figure 35 and Figure 35 a, metal wire locating wheel 504 is the top turnings that are positioned at a metal wire die cavity of take up roll tire parts 414.It should be noted that, metal wire 416 is clamped in the outside of metal wire die cavity by cross-over connection pilot pin 444, be noted that equally when roller tire parts 414 turning anticlockwises, lift cam 528 height that wheel 504 is raised to metal wire die cavity bottom surface that positions the wire will surpass the required numerical value in turning, bottom surface 558 of roller tire parts 414.Because the difference of the interior outer side edges of annular high pressure winding, as shown in figure 39, metal 416 is placed in gives fixed position and just require to promote an added value.Particularly if metal locating wheel 504 does not have attached lifting values, metal wire 416 will be introduced along the last circle coil that has wound, because the effect of tension force, lead 416 is pulled to last circle coil next door.Therefore, avoid such introducing result, just require a new circle coil to be intersected around giving last circle coil, for example in Figure 39, show like that according to giving the interior outer side edges coil configuration pattern of regulation earlier.Additional lifting values, then the maximum transverse force that is acted on the metal wire by metal wire locating wheel 504 just can not be realized the intersection that last circle winds the line.The maximum transverse force that metal wire locating wheel 504 acts on the metal wire is the function of the coiling stress and groove 506 degree of depth.If cross force is excessive, metal wire 416 will skid off from metal wire locating wheel 504, hinder the continuation of metal wire 416 accurately to locate.So just metal wire 416 must be resetted so that reorientate on metal wire locating wheel 504.Therefore, when adding lifting values, because the guiding force that last circle coil causes, metal wire 416 can skid off from metal wire locating wheel 504.Shown in Figure 35 to 39, additional lifting values has reduced the guiding force of front coil, keeps this power in the maximum transverse force scope of metal wire locating wheel 504.Should be noted that the intersection moulding of metal wire 416 is the tops that occur in the high-tension coil bottom side in order to obtain volumetric efficiency.Shown in Figure 35 a, roller tire parts 414 are when rotary position, and metal wire locating wheel 504 is perpendicular to roller tire axis 417.

In Figure 36 and Figure 36 a, roller tire parts 414 turning anticlockwises, metal wire locating wheel 504 is positioned near the metal wire die cavity inner side edge center at this moment.The axial cross section of die cavity inner side edge is trapezoidal, and shown in Figure 36 a, in other words, the sidewall 560 of metal wire die cavity 562 and 566 shrinks towards inlet 564 places of metal wire die cavity.In order to adapt to this trapezoid cross section, utilize servomotor 490 revolution, metal wire locating wheel 504 is tilted around axis 497, by narrow inlet 564 metal wire is placed in the die cavity.Should be noted that oblique axis 497 contacts with metal locating wheel 504 lower edges, metal wire leaves metal wire locating wheel 504 grooves 506 herein, and this allows castor arm 496 needn't change the axial location of lead 416 and tilts.Metal wire 416 depends on the position of moving sliding base 480 at the axial location of metal wire die cavity 562, and this is by servomotor 464 controls.In addition, for metal wire 416 is put into the metal wire cavity bottom, rotate lift cam 528, castor arm 496 and inclined shaft bearing housing 486 are rotated around z axis 518, metal wire locating wheel 504 just drops in the metal wire die cavity 562, and metal wire 416 is placed near the metal wire cavity bottom.Metal wire regulating wheel 542 keeps the tension force of 3 pairs of metal wires 416 when being noted that owing to the revolution of roller tire, and metal wire just can be attached on the wheel rim of metal wire locating wheel 504 tightly.In other words, guide-localization wheel 504 forces metal wire 416 to give first bending, overcomes the bending that metal wire forms when going into metal wire die cavity 562.This flecition has reduced metal wire and has been arc trend in metal wire die cavity 562 lower surface.Also be appreciated that simultaneously on metal wire die cavity 562 inner side edges 445, the width of the inlet 564 of metal wire die cavity slightly than the thickness of metal wire locating wheel 504 more greatly.

In Figure 37 and Figure 37 a, roller tire parts 414 continue to rotate counterclockwise, and metal wire locating wheel 504 enters in the metal wire die cavity 562 bottom sides.Notice that as shown in figure 37 revolution lift cam 528 enters on the bottom of metal wire die cavity 562 metal wire locating wheel 504, not only will avoid two turnings of metal mold cavity bottom surface, and above-described added value will be arranged.Shown in Figure 37 a, wheel 504 favours vertical line, in addition, 504 one-tenth castor forms of metal wire locating wheel are installed, can rotate around castor axis 568, the bottom of wheel is positioned at left side wall 566 sides that coil sides template 440 tilts, and metal wire 416 just is placed near the bottom corners of metal wire die cavity 562.This castor effect is only arranged, and metal wire locating wheel 504 can't move along the oblique sidewall of metal wire die cavity.In order to place metal wire 416 along oblique sidewall, except the castor effect, servomotor 464 drives slides 480 and comprises the metal wire detent mechanism of metal wire locating wheel 504.Be noted that the castor effect must consider that metal wire 416 is placed in the following angle of turning right of metal raceway 502 in the other direction.In addition, be placed on the center situation of metal wire die cavity, just do not require the castor effect, because metal wire locating wheel 504 does not need to place metal wire along oblique sidewall for metal wire 416.

The castor effect of metal wire locating wheel 504 is individual drive not.Would rather say that the castor gyration is freely to carry out, And and metal wire 416 rely on metal wire tension force or drag and be used for finishing when going into the metal wire die cavity.For example, when servomotor 464 drives slide 480 and the metal wire detent mechanism that comprises metal wire locating wheel 504, the bottom rim of metal wire locating wheel 504 is placed in when determining the position of metal wire 416 on metal wire die cavity 562, shown in Figure 39 a, to take turns 504 at metal wire 416 and pull under the effect of metal wire die cavity left side wall, metal wire locating wheel 504 is just around 568 revolutions of castor axis.In fact the tension force on the metal wire 416 acts on the point of relative castor axis shift on metal wire locating wheel 504 wheel rims, makes the metal wire locating wheel produce the effect of arranging metal wire 416.

Figure 38 and 38a show the situation of the winding second whole circle coil.As shown in figure 38, metal wire 416 is placed on the sidewall 560 of the right, lead die cavity 562 bottoms.For metal wire 416 being placed on the sidewall 560 of the right, servomotor 490 makes castor 496 and metal wire locating wheel 504 rotate around axis 497, the bottom of metal wire locating wheel 504 is placed on the right side, bottom of metal wire die cavity 562, and servomotor 464 drives slides 480 and metal wire locating wheel 504 is come to the right then.

The whole bottom surface that winding process proceeds to metal wire die cavity 562 inner side edges 445 always by the individual layer metal wire till full, shown in Fig. 3 P.Should be noted that the first circle coil is to turn left the end that is placed on metal wire die cavity 562 inner side edges 445 on the angle and turn left on the angle in the end of metal wire die cavity outer side edges 568.The second circle coil is placed near the first circle coil.Then, turn right on the angle in the end that the 3rd circle coil is placed in metal wire die cavity 562 inner side edges 445, is placed in 2/3rds places (counting from the first circle coil) of the outer side edges 568 transversal distances of metal wire die cavity when the 3rd circle coil.Then the 4th circle line is placed between metal wire die cavity inner side edge 445 centers, second circle and the 3rd circle line, respectively with second circle and the wedging of the 3rd circle line, tightly fills up the bottom of metal wire die cavity inner side edge 445.Thereafter each circle coil such as the 5th, six are placed in the top of first layer line of metal wire die cavity inner side edge 445, until first layer line of metal wire die cavity 562 outer side edges 568 when filling up till.First layer line of metal wire die cavity outer side edges 568 is arranged tight by same last circle coil of wedging.Continue coiling, wait after the number of turn that the cake formula style that full coil sides template 440 sidewalls are placed restrictions on requires, this has just become the coil 413 of high pressure winding 60.

First complete coil 413 at first metal wire die cavity 562 after intact, lift cam servomotor 524 lifts metal wire locating wheel 504 from the metal wire die cavity, under the manipulation of servomotor 464, slide 480 is being with metal wire locating wheel 504 to move on to next metal wire die cavity.This moves is to be in such position at roller tire parts 414 to take place: can make metal wire 416 around lead intersection pilot pin 444 1 circles, as shown in figure 33.Then, next coil 413 usefulness above-described with quadrat method in next metal wire die cavity.It should be noted that, the accurate axial location of metal wire 416 in the metal wire die cavity, be according to being stored in the computer numerical control device about the measured axial location value of the sidewall of coil sides template 440, relying on metal wire locating wheel 504 to decide in axial exact position.Therefore, numerical value of computer numerical control device servomotor 464 revolution, its size equal slide 480 from the residing position of a coil of coiling to the measured moving range in the next residing position of coil of coiling.

After whole metal wire die cavities of roller tire parts 414 all are wound into cake formula pitch of the laps 413, the end Qie Duan And of metal wire 416 is fixed, roller tire parts are removed from high-tension coil coil winding machine 400.Load onto the axial location that a new roller tire parts ， And accurately measures metal wire 562 then.Then, connect as above-mentioned operation coiling in each metal wire die cavity successively.

After unloading lower roll tire parts 414, each coil of metal wire 416 is linked together, for example coat the thermal welding coating at metal wire 416 with the hot weld device.Can produce this heat from baking oven or by thermocurrent by metal wire 416.Metal wire 416 is connected, and is in order to protect the shape of giving the coil that is shaped earlier and to remain on the metal wire that gives on the allocation.

Shown in Figure 40 and the 40a is the concrete device of preferentially selecting for use of metal wire positioner 770.Metal wire positioner 770 has a radial extent handle 772, and the cross section of this handle is less than the narrowest mouth 564 of roller tire 414 cake formula annular metal cord die cavities 562.Handle 772 is loaded on the axle 774, and axle links successively with a transmission device (not having diagram), and this transmission device makes axle 774 and handle 772 make rotary oscillation, and carries out synchronously with the revolution of roller tire.Metal wire positioner 770 is normally L shaped, and the leg 776 that protrudes in a garden week is arranged, and can stretch in the die cavity 562.Metal wire guide head 770 can be contained on the leg 776, can be around extending radially out the axis revolution.Metal wire guide head 778 is the U font part that concave surface is downward preferably, and it has a screw to stretch out from the U-shaped face and passes the hole of leg 776.An available so suitable nut (as shown) guarantees the rotation of 778 pairs of legs of guide head.Each sidewall of metal wire guide head 778 is respectively axially separately, to compress metal wire 416 but can allow it freely pass through ， And and sidewall the thinnest, can closely metal wire 416 be placed on the pinch wall 560 and 566 of groove 562.

In the operating process of the concrete device of preferentially selecting for use shown in Figure 40 and the 40a, handle 772 is around variable angle value of its coiling (simultaneous with the gyration of roller tire 414) swing, metal wire positioning head 778 is placed on the position in above-mentioned metal wire die cavity 562 constriction, the big I of angle of oscillation realizes that by program control or with a cam follow-up device latter invests and axle 774 cranks that are connected.Metal wire positioning head 778 has determined the position of metal wire 416 562 li of metal wire die cavities in the position of 562 li of metal wire die cavities.Though the thickness of metal wire definite value 778 sidewall has been determined the tightness degree that 416 pairs of walls 560 of lead and 566 are placed, but still after can using a circle " wedging " coil described in Figure 39 and putting into, moving metal line 416 makes it to contact with wall 560 or 566.

Must be noted that, the axial dimension of metal wire positioning head 776 can shrink the axial width of the narrowest inlet 564 partly greater than metallic channel 562, because of metal wire positioning head 778 can be from the punctured position that enters the mouth and be inserted into the top ， And of bottom side 564 and move to metal raceway 562.Anyway, for obtain in the narrowest inlet 564 borders fixed revolution degree, be necessary to make the size of handle 772.

The modified model 780 of the concrete device that metal wire orienting device shown in Figure 41 is preferentially selected for use.This improved concrete device 780 of preferentially selecting for use has a garden handle 782, and there is a leg that stretches out towards periphery 784 corner of garden handle.786 usefulness melting welding of U-shaped bar or steel solid welding are due to the end of leg 784.The U-shaped bar is closely clamped metal wire 416, but allows it freely to pass through.The improved concrete device of preferentially selecting for use 780 is identical with main method of operation and concrete device 770, and therefore, no longer repeat in its operating process this place.

Being described as follows of magnetic core up-coiler

Figure 42 is total figure of magnetic core coil winding machine 600, this machine is used for core material 602 is wound on completed low pressure and high pressure winding, the magnetic core coil winding machine has two main parts: magnetic core is involved in machine 604 and material and rolls up 606, two parts of machine and handle by servo controller 608.In brief, material rolls up machine 606 with continuous magnetic core band, earlier delivers to magnetic core around good And through the material volume 614 of annealing and is involved in machine 604 from giving, and is rewound on the bobbin, becomes the magnetic core 20 of a toroidal transformer 10.

Material is rolled up machine 606 and is contained a base 610 together with horizontal rotation platform 612, and the latter is supporting giving around strip coil 614 of annealed magnetic core band 602, rotates around vertical axis under the control of motor 616.Motor 616 is servomotors, via 30: 1 straight-tooth reduction box of transmission velocity ratio, 618 driving rotational platforms 612.Also have two horizontal rail 620 and 622 at base 610 tops, be positioned at the base top surface both sides, both are parallel to each other.On track 620 and 622, laid a guide chute device 624.Adorning rail-guided seat 626 on the base plate 628 of guide chute device 624, this opening shape matches with horizontal rail 620 and 622, allows guide chute device 624 to do the front and back sliding motion along horizontal rail 620 and 622.Guide chute device 624 also has a pair of vertical end frame 630 and 632.Vertical end frame 630 and 632 respectively have among a pair of vertically-guided axle bed 634(figure only illustrate one), they and vertical guide rail 636 are slidingly matched.Vertical guide rail 636 also is installed on end plate 638 and 640, and when vertical guide rail 636 slided in vertically-guided axle bed 634, end plate 638 and 640 just moved up and down thereupon.Laterally leadingly be positioned at side plate 638 and 640, slightly tilt with vertical line, as shown to swash plate 642.The guide chute device also comprises horizontal back guiding swash plate 644, between two swash plates of front and back, for example separates with a suitable liner, forms a space, and magnetic band 602 can therefrom pass.Space between two swash plates of front and back can be adjusted with the liner of different length.

Shown in Figure 43 is the detail drawing that material rolls up machine 606.From Figure 43, can see motor 616 via straight-tooth reduction box 618, drive panoramic table 612, the situation that magnetic core band 602 is sent.Magnetic core band 602 leaves and gives behind strip coil 614, through laterally back guiding swash plate 644 and laterally leading straight channel 672 between swash plate 642, is sent material and rolls up machine 606.Elucidated hereinafter, when loose winding, straight channel 672 also with the motor coordination of magnetic core band 602, strip coil is produced a reaction force, can prevent that producing strip coil kinks phenomenon.Giving under the motionless situation of strip coil 614, straight channel 672 can be done side-to-side movement by horizontal rail 620 and 622, and does not show bright by vertical guide rail 636(Figure 43) move up and down.In addition because side plate 638 and 640 with vertical end frame 630 and 632 between be to connect with pivot, the inclination angle size of straight channel 672 is with bolt 678 plates 674 of trough of belt 676 firmly tightly, regulates and fixes.One bearing rod 699 is arranged on the horizontal leading swash plate 642, and this bar can not turn round, but has smooth curved surface, and magnetic core band 602 can pass through from it, can avoid magnetic core band 602 to form dog leg at leading upper end to swash plate 642 like this.

Many small through hole 680 that all are spaced in level and vertical direction are arranged on the back guiding swash plate 644.Back guiding swash plate 644 has a vent hood 682, and the individual air chamber 684 that links with each through hole 680 is arranged in the cover.Compressed air source 686 is communicated with air chamber 684 via adjuster valve 689 and suitable flexible pipe 688.Entering the air velocity of air chamber 684, promptly via the throughput in hole 680, is with the frictional force between the back guiding swash plate 644 of choke valve 689 adjusting magnetic core bands 602 and straight channel 672, controls.

The air bearing bearing that air-flow by hole 680 forms, it usually is used to eliminate friction when band 602 passes straight channel 672, not equal to when it passes straight channel 672 at band 602, because the cause of gravity and friction (direction of arrow 690) makes band 602 produce a certain size reaction force.At the reaction force of arrow 690 directions, effectively magnetic core band 602 is pushed to the internal diameter of the roll coil of strip 614, when making magnetic core band 602 leave the roll coil of strip 614 the insides, maintain needed enough little angle of bend, kink phenomenon to avoid producing.If there is not the reaction force of arrow 690 directions, then when magnetic core band 602 left its winding position, its angle of bend was excessive, can produce the fracture induced stress in magnetic core band 602.Because straight channel 672 is moved magnetic core band 602 up, the gravity of magnetic core band has just constituted reaction force.

By the gravity and the reaction force (arrow 690 directions) that rub form of magnetic core band 602 at passage 672, can prevent the dog leg that band 602 is produced when leaving the roll coil of strip 614 the insides effectively and kink phenomenon, this reaction force also can be obtained by the additive method except that gravity and frictional force, as using the magnetic energy of the permanent magnet generation that is placed on the revolution table top or on cambered plate 693 inner radial surface, as shown in figure 44.Panoramic table 612 can become with nonmagnetic substance such as aluminium or copper, and electromagnet is placed on below the panoramic table, by non magnetic turntable 612, the strip coil 614 of annealing is carried out part encourage.

Magnetic core band 602 gives around the path of strip coil 614 the insides from panoramic table 612, can clearly see from Figure 44.Magnetic core band 602 was giving around strip coil and on by straight channel the time before straight channel 672 tops carry out the transition to horizontal direction, up the path movement that tilts with panoramic table 612.When the magnetic core band was dismantled around material volume 614 from giving, this slant path can make the bending of band 614 reduce to minimum degree.

As shown in figure 44, panoramic table 612 has many spaced-apart posts 691, inserting on week in a garden against cambered plate 693, its internal diameter of forming the garden cylindricality is a bit larger tham the external diameter that gives around strip coil 614, so just can make strip coil 614 accurately concentric with the turning spur of panoramic table 612.Cambered plate 693 has a permanent magnet, is used for holding giving around strip coil 614 zone circles.Magnetic attraction is easy to make band 602 to draw off, especially when several astragal materials 602 are stayed in the material volume 614.Because only surplus several astragals were rolled up 614 o'clock, its shortage in weight is to prevent the slip and the rotation of 614 pairs of panoramic tables 612 of the roll coil of strip.The magnetic attraction of a few astragal materials in the outside of the roll coil of strip 614 and cambered plate 693 has prevented the revolution of the roll coil of strip, and magnetic core band 602 can be drawn off from giving around strip coil 614 smoothly.As mentioned above, the magnetic force that cambered plate 693 is provided also can help to produce the reaction force along arrow 690 directions.

Figure 44 shows that also material is rolled up on machine 606 bases 610 four turntable bogie wheels 695 are housed, and all is positioned at turntable 612 gardens near week, is used for supporting the weight around volume 614 of giving of panoramic table 612 and band 602.Bogie wheel 695 has advantageously been placed restrictions on desired other sizes of bearing and the intensity that is used to support panoramic table 612 center power transmission shafts.

Figure 44 shows that also material rolls up the leading to swash plate 642 of machine 606, because its right-hand member has hinge 697 and right-hand member that a latch (not illustrating among the figure) is arranged, can open it, and loads onto strip coil 614 at an easy rate.

Magnetic core is involved in machine 604 and contains a framework 650 as shown in figure 42, is used for supporting by high pressure winding 69, low pressure winding 40, and each insulating case 30 and 50 transformer parts of being formed 652 between each winding and between winding iron core.In addition, transformer part 652 comprises that also a bobbin 692(is as shown in figure 45), this pipe has the axle sleeve of a band internal tooth.

Magnetic core is involved in the control servomotor 654 of machine 604 and is handled by servo controller 608, it drives with control servomotor 616 synchronous, and this is to be complementary in order to make around the feed speed of the magnetic core band 602 of going into transformer part 652 and the speed that draws off magnetic core band 602 from the strip coil 614 of having annealed.Motor 654 is by chain transmission and sleeve 740(as shown in figure 48) connect, sleeve and gear shaft 656 mesh, and see Figure 42 a.Have on the gear shaft 656: two gear parts 658 are separated by a slot portion each other; Engage sleeves part 660 contains a J-shaped groove, as shown; A handwheel 662 and a bearing 664.The J-shaped groove 661 of engage sleeves part 660 cooperates with key (not illustrating among the figure) in the sleeve 740, so that motor 654 driving pinions 658.The internal tooth ， And of pinion 658 engagement bobbins 692 rotates bobbin 692.Gear shaft 656 by two bearings plate 666(only one be shown among Figure 42) supporting, this two plate is installed on the both sides of transformer part 652.

Transformer part 652 by one movably support 670 be placed in core and be involved in the machine, this support has two hypotenuses, be used for thereon transformer part 652 folders, as shown in figure 42, support 670 relies on a suitable elevating mechanism to come lifting, transformer part 652 is risen and fall, describe in detail and see Figure 47 and Figure 48.

Magnetic core band 602 rolls up output the machine 606 from material, via free roller transfer band 671, is directed to bobbin on transformer part 652.Conveyer belt 671 has curve transition portion gradually, and for the needs of the band 602 that adapts to different-thickness and different curvature, conveyer belt 671 is adjustable.

Magnetic core band 602 enters the path that magnetic core is involved in machine 604, can be known by Figure 45 and find out.Be used for controlling band 602 among Figure 45 around each part of going into coil winding machine 692, all illustrate.The roller 694 of free roller transfer band 671, is supported in band 602 on the horizontal level after material rolls up machine 606 outputs at magnetic core band 602.Band 602 is below the edge of a knife under the clamping 696, and this edge of a knife is made by spring material, at the magnetic core winding process, adds the load that bears magnetic core band 602 and throws off to prevent band 602.This disengagement phenomenon is contingent, has tangled the side flange of bobbin 692 when rolling up such as magnetic core band 602.When being noted that bobbin 692 revolution, the magnetic core volume 698 of magnetic core band is just finished giving in low-tension transformer winding and high-tension transformer winding.By finding out among the figure, bobbin 692 contains internal tooth 700, the pinion 658 Nie He And driving shafts 656 of this internal tooth and tooth axle.Bobbin 692 at large discloses in Fig. 6.

In order to guarantee tight coiling magnetic core volume, used traction belt 704, it is connected with friction with the outer rim of magnetic core volume.Belt 704 is crossed first horizontal belt wheel 706, puts in bobbin 692 downwards, and then, belt is walked around the garden week of magnetic core volume 698 counterclockwise and passed through pressure vacuum case 712.Vacuum tank 712 contacts slidably with the limit of traction belt 704, makes in the kerve 718 of vacuum tank 712 to keep by an air compressor 720 or parital vacuum that other vacuum sources provided.Vacuum in the kerve 718 of vacuum tank 712 produces different pressure to traction belt 704, with the downward towing of belt.After belt is tensioned, between belt 704 and magnetic core volume 698, produce friction, handling magnetic core volume 698 whereby.Should be noted that most of circumferential contact that belt 704 and magnetic core are rolled up 698 cylindricals, for example about 270 ° or more, pulling force just is evenly distributed in magnetic core and rolls up on 698 like this.

Figure 46 has clearly illustrated that the correlation of clamping plate angle fork 696 with traction belt 704.Bobbin 692 shown in Figure 46 is the situations before the arbitrary core material 602 of coiling.By looking along arrow 46 directions among Figure 45, clamping plate angle fork 696 is the two side ends that is positioned at bobbin 692 inside, with the two side ends engagement of magnetic core band 602.Drawing belt 704 is positioned at the mid point of 696 of two clamping plate angles forks approximately.On every limit of bobbin 692 a garden post guide thimble 722 is arranged all, be used for magnetic core band 602 is imported bobbin 692.Guide thimble 722 is to be made by high-abrasive material such as carbide, can be used to prevent that magnetic core band 602 from producing new wear surface around its axis adjustment rotation.

Figure 47 and shown in Figure 48 be the supporting positioning device of transformer part 652.The effect of this supporting positioning device, it is position alignment with the tooth and the bobbin power transmission shaft 656 of bobbin 692, and half and half garden part of the sub-unit that will wind the line is launched, form the notch of a maximum, be used for controlling and sending magnetic core band 602 on bobbin 692, keep the concentricity of coil assembly half and half garden part, this concentricity is necessary, because guarantee that bobbin can turn round continuously in winding process, need a toroidal core cavity.

Support 670 is contained on the water surface slide plate 724, and this plate is installed on the hoistable platform 726 by a parallel sliding track and sliding with it four guide grooves 730 of joining again.Because horizontal slide plate 724 is slidably, support 670 can be to front slide (promptly outside framework 650), and this just makes transformer part 652 before and after the magnetic core winding process, can easily move and locate.Hoistable platform 726 is that the lift-bolt 732(that is installed in the setting of a pair of oblique angle with jacknut 736 and fairlead 738 respectively only shows one in the drawings) and the guide post 724 that is provided with of a pair of oblique angle on.The elevating movement of the rotation of lift-bolt 732 and hoistable platform 726 is synchronous (transmission device is not shown), so, along with the lifting of support 670 magnetic core component 652 is determined that accurately drive socket 740(is used for drum stand power transmission shaft 656) relative position.

Application is installed in the easy transmission position of accurately determining core components 652 and drive socket 740 of variable fine-tuning mechanism between horizontal slide plate 724 and the support 670.Variable fine-tuning mechanism 744 can be made up of a sliding wedge, and this voussoir is used for lifting inner panel 742(support 670 peaces thereon), perhaps form by a low-pressure hydraulic piston and air cylinder device.Fine setting machinery 744 can be used as the Height Adjustment mechanism of lift-bolt 732 and jacknut 736 effectively, height to support 670 is finely tuned, so that accurately transformer part 652 is fixed in the drive socket 740, make the tooth 700 of bobbin 692 can be well and pinion 658 engagements of bobbin power transmission shaft 692.This configuration as shown in figure 48, two of bobbin 692 groups of teeth 700 are with tooth 658 engagements of two groups of bobbin power transmission shaft 656 pinions among the figure.

Finish the accurate location of the transformer part 652 also routing motion of useable holder 670 and voussoir introducing mechanism 746.Introducing mechanism 746 is suitable for two semi-circular portions of transformer part are forced spreading, to form an actual maximum admission passage, makes magnetic core band 602 around going into.Especially, cotter mechanism 746 comprises a pair of axially spaced wedge shape part 748a and 748b.The two sides of wedge shape part form 30 ° of angles, are suppressed among two semi-circular portions of transformer part 652.Like this wedge shape part 748 is pressed into by force, the arc notch bottom between two semi-circular portions of transformer part 652 is just by obturation, so 30 ° of angles are opened on the arc notch top between two semi-circular portions of transformer part 652.Go up arc notch and open 30 ° of angles, just at an easy rate with magnetic core band 602 around going into.

Can see that equally wedge shape part 748 axially separates fully from Figure 48, magnetic core band 602 whole width just can freely enter.In addition, by support 670 and the 748 formed supported at three points of wedge shape part, the stationary transformer parts 652 tightly, and the position of the arcuate channels of transformer part just can be with one heart.The position of the arcuate channels of transformer part two semicircles needs with one heart, is in order to allow ring winding pipe 692 freely to rotate in transformer part 652.If the arcuate channels wall of transformer part 652 can not become annulus completely, then bobbin 692 can be lived by volume and scratch magnetic core insulated tube 30, thereby the driving force of bobbin is greatly increased, and the danger that marks striped is arranged on the tooth of bobbin.

Should be noted that the concentric arrangement of transformer part 652, the pinion 658 that also requires power transmission shaft 656 is accurately aimed at the tooth 700 of bobbin 692.The correct engagement of pinion and bobbin tooth, the three-point support that also can easily use wedge shape part 748 and support 670 is provided is realized.

Wedge shape part 748 is to rely on air slide and cylinder 750 to come positive motion, and an end of piston and center bifurcated working arm 752 is with pivotally connected.The other end of working arm 752 be fixed in fulcrum 754 on the framework 650 also with pivotally connected.Working arm is heart position bifurcated therein, forms two axially spaced center arm 756.Each axially spaced center arm 756 borrows short connecting rod 758 and wedge shape part 748a or 748b links and its position alignment.Short connecting rod 758 and each center arm 756 be with pivotally connected, and be connected securely with wedge shape part 748a or 748b.Each connecting rod 758 pivotally connected, the position that allows wedge shape part 748 to calibrate depressor parts 625 voluntarily.With piston and cylinder 750 compressions, wedge shape part 748 is forced to move downward, and the last arc notch of transformer part 652 has obtained aforesaid accurate calibration just by spreading.

Transformer by spreading and calibration after, power transmission shaft 565 revolution, with magnetic core band 602 on bobbin 692.Synchronous machine 654 makes power transmission shaft 656 revolutions via driving belt and coupling 740, and is as above illustrated.When magnetic core band 602 around fashionable, the outermost friction engagement of traction belt 704 and core const ruction keeps magnetic core band 602 that a winding is very closely arranged.Elasticity blade 696 is from radially pushing down magnetic core band 602, prevents that magnetic core band 602 from deviating from because of the interlock of chance is bad at side flange 698 places of bobbin 692.When magnetic core piece coiled, traction belt 704 is removed, to eliminate the shared space of belt 30, make last several circles of magnetic core band 602 can be on bobbin 692.Magnetic core is removed wedge shape part 748, is fallen support 670 after finishing, and outwards promotes horizontal slide plate 724, then transformer part is involved in machine 604 from magnetic core and takes off.After this, transformer part 652 is rotated, make 15 ° of arc notches that between two semicircle winding portions, provide impartial.Then liner 80 is filled in, coiling position is partly fastened.

Above-mentioned explanation discloses and has narrated multiple typical method of the present invention and concrete device.Any those skilled in the art that can easily reach a conclusion, and the generation of various variations, improvement and modification must not break away from the scope of content of the present invention and claim.

Claims (6)

1, a kind of equipment of making toroidal transformer, this equipment with the magnetic core band from the inner ring of core material volume deviate from and with the magnetic core band around go into toroidal transformer in advance around the primary and secondary winding, this equipment comprises:

The direction rotation that a turntable, this turntable make core material reel its axis and unclamp continuously the inner ring of volume towards the magnetic core band from core material;

A coiler device, be used for the magnetic core band above-mentioned around going in advance around the primary and secondary winding,

It is characterized in that: this equipment also comprises an orienting device, be used for accepting rolling up the magnetic core band of deviating from and keeping the magnetic core band to leave the direction of core material volume from core material, a device that produces resistance, this device is pushed band the inner ring of core material volume to the resistance that band produces, and minimum degree is reduced in the bending when making band leave inner ring.

2, specially require 1 described equipment according to power, it is characterized in that above-mentioned device and the above-mentioned orienting device that the magnetic core band is produced resistance works to the magnetic core band jointly, band is applied a frictional force in the opposite direction of magnetic core ribbon motion.

3, equipment according to claim 2 is characterized in that described orienting device relies on gravity that band weight produces to push the magnetic core band inner ring of core material volume to, makes the band of deviating from from inner ring always towards the direction that makes progress.

4,, it is characterized in that described turntable is around the concentric axis rotation of itself and core material volume according to the described equipment of claim 1,2 or 3.

5, a kind of method of making toroidal transformer, this method be with the magnetic core band from the inner ring of core material volume deviate from and with the magnetic core band around go into toroidal transformer in advance around the primary and secondary winding, its step is as follows: utilize the reel rotation of its axis of core material that material webs is deviate from from the direction that inner ring unclamps continuously, the band that to deviate from around go into above-mentioned in advance around the primary and secondary winding in, it is characterized in that: accept the band of from the core material volume, deviating from and keep band to leave the direction of material webs, the magnetic core band is produced a resistance, when material webs is unclamped, this resistance is pushed band the inner ring of material webs to, and minimum degree is reduced in the bending when making band leave material webs.

6, toroidal transformer of making according to the described method of claim 5.

Images